Yanmar 6 SY-STP2

6SY / 8SY Service Manual
SY
series
SERVICE MANUAL
6SY-STP2
6SY655
8SY-STP
P/N: 0BSYM-G00100
MARINE
ENGINES
This Service Manual has been developed for the exclusive use of service and repair professionals such as
Yanmar authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in
mind and may not contain the necessary detail or safety statements that may be required for a
non-professional to perform the service or repair properly and / or safely. Please contact an authorized
Yanmar repair or service professional before working on your Yanmar product.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available
at the time of publishing. The illustrations used in this manual are intended as representative reference
views only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenance
improvement. We reserve the right to make any change at any time.
Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and /
or other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems -
without the written permission of Yanmar Co., Ltd.
© 2007 Yanmar Marine International.
0107
ii
TABLE OF
CONTENTS
Page
Table of Contents .................................................................................. 2-i

Introduction ......................................................................................... 1-1
Safety.................................................................................................... 2-1
General Service Information .............................................................. 3-1
Periodic Maintenance ......................................................................... 4-1
Engine .................................................................................................. 5-1
Fuel System ......................................................................................... 6-1
Cooling System ................................................................................... 7-1
Lubrication........................................................................................... 8-1
Turbocharger ....................................................................................... 9-1
Starter Motor...................................................................................... 10-1
Alternator ........................................................................................... 11-1
EMS..................................................................................................... 12-1
Troubleshooting ................................................................................ 13-1
6SY / 8SY Service Manual iii

TABLE OF CONTENTS
This Page Intentionally Left Blank
iv 6SY / 8SY Service Manual

Section 1
INTRODUCTION
This manual gives specific instructions for the
proper repair of Yanmar SY series marine engines.
Please follow the procedures carefully to ensure
quality service.
Yanmar recommends that you read this Service
Manual completely before starting with repairs.
Along with standard tools, Yanmar recommends the
use of special tools, necessary to perform repairs
correctly.
Yanmar products are continuously undergoing
improvement. This Service Manual has been
checked carefully in order to avoid errors. However
Yanmar is not liable, for any misrepresentations,
errors of description or omissions. Contact an
authorized Yanmar marine dealer or distributor for
any questions you have regarding this Service
Manual.
6SY / 8SY Service Manual 1-1

INTRODUCTION Revision History
REVISION HISTORY
This manual is a living document. Periodic manual At times, the revision involves inserting additional
revisions are published to document product pages in one or more sections. Replace the
improvements and changes. This practice ensures Revision Control Table and insert the new pages.
the manual has the most current information.
This method of revision control represents the most
As manual revisions become necessary, individual cost-effective solution to providing current, updated
pages are prepared and sent to those who need information as needed.
the information. If a page, or number of pages
should be replaced, the replacement information is
sent along with a revised Revision Control Table.
Discard the older, obsolete information.
Revision Control Table

Revision Date New Page Numbers Initiating
Remarks
Revision Number Involved Dept.
DEC 2006 All Re-release YMU
Rev. 01
JAN 2007 7-4 Corrected torque value for seawater pump gear nut YMU
Rev. 02 7-28
1-2 6SY / 8SY Service Manual

Section 2
SAFETY
Yanmar is concerned for your safety and the
condition of your marine engine. Safety statements
are one of the primary ways to call your attention to Indicates a hazardous situation which, if not
the potential hazards associated with Yanmar avoided, will result in death or serious injury.
marine engines. Follow the precautions listed
throughout the manual before operation, during
operation and during periodic maintenance
Indicates a hazardous situation which, if not
procedures for your safety, the safety of others and
avoided, could result in death or serious injury.
to protect the performance of your marine engine.
Keep the decals from becoming dirty or torn and
replace them if they are lost or damaged. Also, if
you need to replace a part that has a decal Indicates a hazardous situation which, if not
attached to it, make sure you order the new part avoided, could result in minor or moderate
and decal at the same time. injury.
This safety alert symbol appears
A
with most safety statements. It Indicates a situation which can cause damage to
means attention, become alert, the machine, personal property and / or the
your safety is involved! Please read environment or cause the equipment to operate
and abide by the message that improperly.
follows the safety alert symbol.

SAFETY Safety Precautions
SAFETY PRECAUTIONS
The safety messages that follow have
WARNING level hazards.
The safety messages that follow have DANGER
level hazards. Explosion Hazard
Avoid serious personal injury or
There is no substitute for common sense and
equipment damage. While the engine is
careful practices. Improper practices or
running or the battery is charging,
carelessness can cause burns, cuts, mutilation,
hydrogen gas is being produced and
asphyxiation, other bodily injury or death. This
can be easily ignited. Keep the area
information contains general safety precautions
around the battery well-ventilated and keep sparks,
and guidelines that must be followed to reduce risk
open flame and any other form of ignition out of the
to personal safety. Special safety precautions are
area.
listed in specific procedures. Read and understand
all of the safety precautions before operation or
performing repairs or maintenance. Avoid serious personal injury or equipment
damage. ALWAYS turn off the battery switch (if
equipped) or disconnect the negative battery cable
Avoid injury or equipment damage due to engine
before servicing the equipment.
falling. ALWAYS secure the engine solidly to
prevent the engine from falling during maintenance.
Avoid unexpected equipment movement. Shift the
NEVER permit anyone to install or marine gear NEUTRAL any time the engine is at
operate the engine without proper idle.
training. Fire Hazard
Avoid personal injury or equipment
◆Read and understand this Operation
damage. Have appropriate safety
Manual before you operate or service the
equipment available.
engine to ensure that you follow safe operating
practices and maintenance procedures.
◆ Safety signs and decals are additional ◆ Keep fire extinguishers handy in case of fire.
reminders for safe operating and maintenance Clearly indicate the location of the fire
techniques. extinguishers with a safety sign.
◆ See your authorized Yanmar marine dealer or ◆ Ensure that the type of fire extinguishers are
distributor for additional training. appropriate for material that might catch fire.
Check with local authorities.
◆ Have all fire extinguishers checked periodically
for proper operation and / or readiness.
◆ Post evacuation routes prominently.
Periodically conduct fire drills.
Avoid personal injury. ALWAYS read and follow

safety-related precautions found on containers of
hazardous substances like parts cleaners, primers,
sealants and sealant removers.
Wipe up all spills immediately.

Safety Precautions SAFETY
12/05
Electrical Hazard
Make welding repairs safely.
Entanglement Hazard
◆ALWAYS turn off the battery switch (if
Rotating parts can cause severe injury
equipped) or disconnect the negative
or death. NEVER wear jewelry,
battery cable and the leads to the
unbuttoned cuffs, ties or loose fitting
alternator when welding on the
clothing and ALWAYS tie long hair
equipment.
back when working near moving / rotating parts
◆ Remove the multi-pin connector to the engine
such as the flywheel or PTO shaft. Keep hands,
control unit. Connect the weld clamp to the
feet and tools away from all moving parts.
component to be welded and as close as
possible to the welding point.
Avoid personal injury. ALWAYS stop the engine ◆ NEVER connect the weld clamp to the engine
before beginning service. or in a manner which would allow current to
pass through a mounting bracket.
Avoid personal injury. NEVER leave the key in the ◆ When welding is completed, reconnect the
key switch when servicing the engine. Attach a “Do leads to the alternator and engine control unit
Not Operate” tag near the key switch while prior to reconnecting the batteries.
performing maintenance on the equipment.
Exhaust Hazard
Sever Hazard Avoid serious injury or death. NEVER
block windows, vents, or other means
Avoid personal injury. The propeller
of ventilation if the engine is operating
may rotate during towing or if the
in an enclosed area. All internal
engine is running at idle speed.
combustion engines create carbon monoxide gas
NEVER service the marine gear while
during operation and special precautions are
being towed or when the engine is running.
required to avoid carbon monoxide poisoning.
Avoid personal injury. If the vessel has more than

Burn Hazard
one engine, NEVER service a marine gear if either
of the engines are running. In multi-engine Avoid serious injury. Some of the engine
configurations the propeller for an engine that is surfaces become very hot during
shut down may rotate if any of the other engines operation and shortly after shut down.
are running. Keep hands and other body parts away
from hot engine surfaces.
Rotating parts can cause severe injury or death.
NEVER operate the engine without the guards in Handle hot components with heat-resistant gloves.
place.
Sudden Movement Hazard
Avoid personal injury. NEVER operate the engine Avoid personal injury or equipment damage. The
while wearing a headset to listen to music or radio engine lifting eyes are engineered to lift the weight
because it will be difficult to hear the warning of the marine engine only. ALWAYS use the engine
signals. lifting eyes when lifting the engine.
To prevent accidental equipment movement,

NEVER start the engine in gear.

Lifting Hazard The safety messages that follow have CAUTION

Avoid serious personal injury. Additional equipment level hazards.
is necessary to lift the marine engine and marine Avoid personal injury. ALWAYS wear
gear together. ALWAYS use lifting equipment with eye protection when servicing the
sufficient capacity to lift the marine engine. engine or when using compressed air
or high-pressure water. Dust, flying
If you need to transport an engine for repair have a debris, compressed air, pressurized
helper assist you attach it to a hoist and load it on a water or steam may injure your eyes.
truck.
Poor Lighting Hazard
Alcohol and Drug Hazard Avoid personal injury or equipment damage.
NEVER operate the engine while you Ensure that the work area is adequately
are under the influence of alcohol or illuminated. ALWAYS install wire cages on portable
drugs or are feeling ill. safety lamps.
Tool Hazard
Exposure Hazard Avoid personal injury or equipment damage.
To avoid injury, ALWAYS wear personal ALWAYS use tools appropriate for the task at hand
protective equipment including and use the correct size tool for loosening or
appropriate clothing, gloves, work tightening machine parts.
shoes, eye and hearing protection as
required by the task at hand.
Tool Hazard
Avoid personal injury or equipment damage.
Always remove any tools or shop rags used during
maintenance from the area before operation.

Safety Precautions SAFETY
12/05
Make sure the engine is installed on a level surface.

If a Yanmar Marine Engine is installed at an angle
The safety messages that follow have NOTICE that exceeds the specifications stated in the
level hazards. Yanmar Marine Installation manuals, engine oil may
enter the combustion chamber causing excessive
Any part which is found defective as a result of
engine speed, white exhaust smoke and serious
inspection or any part whose measured value does
engine damage. This applies to engines that run
not satisfy the standard or limit must be replaced.
continuously or those that run for short periods of
time.
ALWAYS tighten components to the specified
torque. Loose parts can cause equipment damage
or cause it to operate improperly.
Only use replacement parts specified. Other

replacement parts may affect warranty coverage.
NEVER attempt to modify the engine design or

safety features such as defeating the engine speed
limit control or the diesel fuel injection quantity
control.
Modifications may impair the engine’s safety and

performance characteristics and shorten the
engine’s life. Any alterations to this engine may void
its warranty. Be sure to use Yanmar genuine
replacement parts.
ALWAYS be environmentally
responsible.
Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous materials such as
engine oil, diesel fuel and engine coolant. Consult
the local authorities or reclamation facility.
NEVER dispose of hazardous materials by
dumping them into a sewer, on the ground or into
ground water or waterways.
If any indicator illuminates during engine operation,

stop the engine immediately. Determine the cause
and repair the problem before you continue to
operate the engine.


Section 3
GENERAL SERVICE
INFORMATION
Page
Safety Precautions .......................................................................... 3-3
Engine Outline Drawings................................................................. 3-4
6SY-STP2 X ZF325-1................................................................ 3-4
8SY-STP X MG5114 IV ............................................................. 3-5
Engine Piping Diagrams.................................................................. 3-6
Location of Nameplates................................................................... 3-9
Engine Nameplate (Typical) ...................................................... 3-9
Diesel Fuel .................................................................................... 3-10
Diesel Fuel Specifications ....................................................... 3-10
Filling the Fuel Tank ................................................................ 3-11
Bleeding the Fuel System........................................................ 3-11
Engine Oil...................................................................................... 3-12
Engine Oil Specifications ........................................................ 3-12
Engine Oil Viscosity................................................................. 3-12
Selection of Marine Gear Oil ................................................... 3-13
Engine Coolant.............................................................................. 3-13
Engine Coolant Specifications................................................. 3-13
Coolant (Closed Cooling System) ........................................... 3-13
Principal Engine Specifications ..................................................... 3-15
Engine Service Standards............................................................. 3-17
Tightening Torques for Standard Bolts and Nuts .......................... 3-18
Tightening Fasteners............................................................... 3-18
Abbreviations and Symbols........................................................... 3-19
Abbreviations........................................................................... 3-19
Symbols................................................................................... 3-19

GENERAL SERVICE INFORMATION
Unit Conversions ............................................................................ 3-20
Unit Prefixes ............................................................................. 3-20
Units of Length ......................................................................... 3-20
Units of Volume ........................................................................ 3-20
Units of Mass............................................................................ 3-20
Units of Force ........................................................................... 3-20
Units of Torque......................................................................... 3-20
Units of Pressure...................................................................... 3-20
Units of Power .......................................................................... 3-20
Units of Temperature................................................................ 3-20

Safety Precautions GENERAL SERVICE INFORMATION
12/05
SAFETY PRECAUTIONS
Fire Hazard
Avoid injury or equipment damage
from fire. Undersized wiring systems
can cause an electrical fire.
Electrical Hazard
Avoid personal injury or equipment
damage. ALWAYS keep the electrical
connectors and terminals clean. Check
the electrical harnesses for cracks,
abrasions, and damaged or corroded
connectors.
NEVER turn off the battery switch (if equipped) or

short the battery cables during operation. Damage
to the electrical system will result.

Figure 3-1
3-4
Sea water inlet, Ø54
Unloaded
6SY-STP2 X ZF325-1
Loaded
Sea water outlet, Ø50.2
247 min/255 max

252 min/260 max
252 min/260 max Unloaded

247 min/255 max Loaded
120
308
n 170
n 140
5
ENGINE OUTLINE DRAWINGS
16
90 90
140 (127.5) 140
2x 355 12x n 16.2 equally spaced
197.5
426.5 1130
Figure 3-1
8x Ø15 Neutral
45° 45
2x n 6.35
Fo
r w se
ar er
d ev
R
Scale 1:2
2x 355

0004485
Engine Outline Drawings
12/05
Figure 3-2
Sea water inlet, Ø54

Engine Outline Drawings
8SY-STP X MG5114 IV
120
TWIN DISC
R
314

14°
Sea water outlet, Ø54 140
ed
ac
5
22
6
256 ±4 unloaded
251±4 loaded
lly sp
256 ±4 unloaded
251±4 loaded
8x n
n 190.
equa .6
n 228.
4.1
17.8
152.4
3x 430 3x 430
61.7
140 140 ( 79 )
277.05 149.5 1104
Figure 3-2
Only electronic conrol valve
12x n 15 TD 1020525
( 430 )
( 430 )
0004484
3-5
GENERAL SERVICE INFORMATION Engine Piping Diagrams
ENGINE PIPING DIAGRAMS Figure 3-48SY Fuel Flow

(1) (2) (8) (3) (4) (12) (5)
Figure 3-36SY Fuel Flow
(1) (2) (8) (3) (4) (5) (9)
(9) (8)
(12)
(8)
(10) (6) (11) (7) 0003538
1 – Fuel Feed Pump Assembly

(10) (6) (11) (12) (7)
2 – Hand Pump
0003537
3 – EMS Control Unit
1 – Fuel Feed Pump Assembly 4 – Fuel Filter
2 – Hand Pump 5 – Cylinders
3 – EMS Control Unit 6 – Fuel Tank
4 – Fuel Filter 7 – Fuel Return Line
5 – Cylinders 8 – Check Valve
6 – Fuel Tank 9 – Feed Pump Gear Set
7 – Fuel Return Line 10 – Safety Valve
8 – Check Valve 11 – Pressure Relief Valve
9 – Feed Pump Gear Set 12 – Bleeder Valve
10 – Safety Valve
11 – Pressure Relief Valve Figure 3-4
12 – Bleeder Valve
Figure 3-3

Engine Piping Diagrams GENERAL SERVICE INFORMATION
12/05
Figure 3-56SY Cooling Flow
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (8) (11) (12) (13) (14) (15) (16)
(17)
(25)
(18)
(19)
(20)
(24 ) (23)
(22) (21)
0004479
1 – Bypass Channel 13 – Cooler for Gearbox Oil

2 – Main Thermostat 14 – Seawater Intake
3 – Water-Cooled Exhaust Manifold 15 – Water-Cooled Turbocharger
4 – Charge Air Coolant 16 – Raiser with Seawater Outlet
5 – Charge Air Coolant Supply 17 – Seawater Outlet
6 – Heat Exchanger Element, Charge Air Cooler 18 – Air Supply to Turbocharger
Section 19 – Air Inlet to Seawater Cooled Charge Air
7 – Static Line Cooler
8 – Venting 20 – Charge Air Cooler with Seawater Cooling
9 – Pressure Cap 21 – Charge Air Cooler with Coolant Cooling
10 – Coolant Recovery Tank (integrated with heat 22 – Air Inlet to Charge Air Cooler with Coolant
exchanger) Cooling
11 – Oil To and From Gearbox 23 – Engine Oil Cooler
12 – Heat Exchanger Element, Main Section 24 – Coolant Pump
25 – Thermostat Housing with Thermostat for
Charge Air Circuit
Figure 3-5

GENERAL SERVICE INFORMATION Engine Piping Diagrams
Figure 3-68SY Cooling Flow
(2)
(3)
(1) (4)
(11) (5)
(6)
(7) (8)
(9)
(10) (11)
(12)
(17)
(13)
(18)
(14)
(19) (20)
(11) (15) (16) (18)
(8) 0004480
1 – Heat Exchanger Element, Main Section 11 – Ventilation Line

2 – Reverse Gear Oil Cooler (Optional) 12 – Thermostats, Main Cooling Circuit
3 – Heat Exchanger Element, Charge Air 13 – Bypass Lines
Section 14 – Static Line
4 – Seawater Outlet 15 – Coolant Pump
5 – Seawater Inlet 16 – Engine Oil Cooler
6 – Coolant to Charge Air Coolers 17 – Coolant from Turbochargers
7 – Thermostat, Charge Air Section 18 – Coolant to Turbochargers
8 – Water-Cooled Exhaust Manifolds 19 – Outlet from Charge Air Coolers
9 – Pressure Cap 20 – Coolant from Block to Charge Air Section of
10 – Coolant Recovery Tank Heat Exchanger
Figure 3-6

Location of Nameplates GENERAL SERVICE INFORMATION
12/05
LOCATION OF NAMEPLATES Figure 3-88SY Engines
The following figures show the location of

regulatory and safety nameplates on Yanmar SY
marine engines.
Engine Nameplate (Typical)

Figure 3-76SY Engines
MODEL
CONT. RATING kW rpm
MAX OUTPUT kW rpm
ENGINE NO.
YANMAR DIESEL ENGINE
0003497
Figure 3-8
MODEL
CONT. RATING kW rpm
MAX OUTPUT kW rpm
ENGINE NO.
YANMAR DIESEL ENGINE
0003496
Figure 3-7
The typical location of the engine nameplates is
shown for Yanmar 6SY Series marine engines
(Figure 3-7).
0003498
Figure 3-9
The typical location of the engine nameplates is
shown for Yanmar 8SY Series marine engines
(Figure 3-8) and (Figure 3-9).

GENERAL SERVICE INFORMATION Diesel Fuel
DIESEL FUEL • Fuel additives are not recommended. Some fuel

additives may cause poor engine performance.
Diesel Fuel Specifications Diesel Fuel Lines
Diesel fuel should comply with the following Figure 3-10
specifications. The table lists several worldwide 1 4

specifications for diesel fuels.
2 3
DIESEL FUEL
LOCATION
SPECIFICATION
No. 2-D, No. 1-D, USA 5
ASTM D975-94 10
EN590:96 European
Union
ISO 8217 DMX International
9
BS 2869-A1 or A2 United 7
Kingdom 8
JIS K2204 Grade No.2 Japan
6
0002050
Additional Technical Fuel Requirements 1 – Fuel Filter

2 – Fuel Priming Pump
• The fuel cetane number should be equal to 45 or
3 – Fuel Filter / Water Separator
higher. 4 – Fuel Return Line
• The sulfur content must not exceed 0.5% by 5 – Fuel Tank
volume. Less than 0.05% is preferred. 6 – Fuel Tank Drain Cock
7 – Approximately 50 mm (1.96 in.)
• Water and sediment in the fuel should not exceed 8 – Fuel Shutoff Valve
0.05% by volume. 9 – Less than 500 mm (19.68 in.)
10 – To Fuel Injection Pump
• Ash content not to exceed 0.01% by volume.
Figure 3-10
• Carbon residue content not to exceed 0.35% by
Install the lines between the fuel tank and the fuel
volume. Less than 0.1% is preferred.
injection pump.
• Total aromatics content should not exceed 35%
Be sure to install a drain cock (Figure 3-10, (6)) at
by volume. Less than 30% is preferred.
the bottom of the fuel tank to remove water and
• PAH (polycyclic aromatic hydrocarbons) content contaminants.
should be below 10% by volume.
Install a fuel filter / water separator (Figure
• NEVER mix kerosene, used engine oil, or 3-10, (3)) and a fuel filter (Figure 3-10, (1))
residual fuels with the diesel fuel. between the fuel tank and the fuel injection pump.
• Never use Biocide or mix winter and summer

fuels.
• Keep the fuel tank and fuel-handling equipment
clean at all times.
• Poor-quality fuel can reduce engine performance
and / or cause engine damage.

Diesel Fuel GENERAL SERVICE INFORMATION
12/05
Filling the Fuel Tank Bleeding the Fuel System

DANGER! Be sure to place the diesel fuel The fuel system needs to be bled under the
container on the ground when transferring the following conditions:
diesel fuel from the pump to the container. Hold
the hose nozzle firmly against the side of the • Before starting the engine for the first time.
container while filling it. This prevents static • After running out of fuel and fuel has been added
electricity buildup which could cause sparks to the fuel tank.
and ignite fuel vapors. NEVER place diesel fuel
or other flammable material such as oil, hay or • After fuel system maintenance such as changing
dried grass close to the engine during engine the fuel filter and draining the fuel filter / water
operation or shortly after shutdown. separator, or replacing a fuel system component.
CAUTION! Only use diesel fuels recommended See Bleed the Fuel System on page 6-17 for
by Yanmar for the best engine performance, to procedure.
prevent engine damage and to comply with EPA
warranty requirements. Only use clean diesel
fuel.
1. Clean the area around the fuel cap. DANGER!
Only fill the fuel tank with diesel fuel. Filling
the fuel tank with gasoline may result in a
fire and will damage the engine. NEVER
refuel with the engine running.
2. Remove the fuel cap from the fuel tank.
WARNING! Wipe up all spills immediately.
Keep sparks, open flames or any other form
of ignition (match, cigarette, static electric
source) well away when refueling.
3. Stop fueling when the gauge shows the fuel
tank is full. NOTICE: NEVER overfill the fuel
tank.
4. Replace the fuel cap and hand-tighten.
Over-tightening the fuel cap will damage it.
DANGER! Store any containers containing
fuel in a well-ventilated area, away from any
combustibles or sources of ignition.

GENERAL SERVICE INFORMATION Engine Oil
ENGINE OIL Additional Technical Engine Oil

Requirements:
Engine Oil Specifications The engine oil must be changed when the Total
NOTICE: Only use the engine oil specified. Other Base Number (TBN) has been reduced to 2.0. TBN
engine oils may affect warranty coverage, cause (mgKOH/g) test method; JIS K-201-5.2-2 (HCI),
internal engine components to seize or shorten ASTM D4739 (HCI).
engine life. NEVER mix different types of engine oil.
This may adversely affect the lubricating properties
Engine Oil Viscosity
of the engine oil. Select the appropriate engine oil viscosity based on
the ambient temperature shown in the SAE Service
Use an engine oil that meets or exceeds the Grade Viscosity Chart in (Figure 3-11).
following guidelines and classifications:
SAE 15W40 is the recommended oil viscosity.
Service Categories Figure 3-11
• API Service Categories CD or higher SAE 10W

SAE 20W
• ACEA Service Categories E-3, E-4 and E-5 SAE 10W-30
SAE 15W-40
• JASO Service Category DH-1
SAE 20
SAE 30
Definitions SAE 40
• API Classification (American Petroleum Institute)

-4˚F 14˚F 32˚F 50˚F 68˚F 86˚F 104˚F
• ACEA Classification (Association des (-20˚C) (-10˚C) (0˚C) (10˚C) (20˚C) (30˚C) (40˚C)
0000005
Constructeurs Européens d’Automobilies)
Figure 3-11
• JASO (Japanese Automobile Standards
Organization)
Note:
1. Be sure the engine oil, engine oil storage
containers, and engine oil filling equipment
are free of sediment and water.
2. Change the engine oil after the first 50 hours
of operation and then every 250 hours
thereafter.
3. Select the oil viscosity based on the ambient
temperature where the engine is being
operated. See the SAE Service Grade
Viscosity Chart (Figure 3-11).
4. Yanmar does not recommend the use of
engine oil “additives.”

Engine Coolant GENERAL SERVICE INFORMATION
12/05
Maximum Angles of Inclination During ENGINE COOLANT

Operation
Maximum permissible angles during operation vary Engine Coolant Specifications
depending on the type of oil sump (Figure 3-12). Use a Long Life Coolant (LLC) that meets or
exceeds the following guidelines and specifications:
Note: The specified angle may only occur
NOTICE: Only use the engine coolant specified.
intermittently.
Other engine coolants may affect warranty
Figure 3-12
coverage, cause an internal buildup of rust and

scale and / or shorten engine life. NEVER mix
different types of engine coolants. This may
adversely affect the properties of the engine
coolant.
25°
• ASTM D6210, D4985 (US)
25° • JIS K-2234 (Japan)
• SAE J814C, J1941, J1034 or J2036
(International)
Note: In the U.S., LLC is required for the
warranty to be valid.
Coolant (Closed Cooling System)

35° 35°
NOTICE: Always add LLC to soft water - especially
0004382 when operating in cold weather. Without LLC,
cooling performance will decrease due to scale and
Figure 3-12 rust in the cooling system. Water alone may freeze
and form ice; it expands approximately 9% in
Selection of Marine Gear Oil volume.
Refer to the documentation supplied with each
marine gear. Use the proper amount of coolant concentrate for
the ambient temperature as specified by the LLC
manufacturer. LLC concentration should be a
minimum of 30% to a maximum of 60%. Too much
LLC will decrease the cooling efficiency also.
Do not mix different types or brands of LLC or a

harmful sludge may form.
Do not use hard water. Use deionized water.

Water should be clean and free from sludge or
particles.

GENERAL SERVICE INFORMATION Engine Coolant
Follow the manufacturer’s recommendations. Use a

proper LLC which will not have any adverse effects
on the materials (cast iron, aluminum, copper, etc.)
of the engine’s fresh-water cooling system. See
Engine Coolant Specifications on page 3-13.
Replace engine coolant periodically, according to
the maintenance schedule in the Operation
Manual.
Remove scale from the cooling system periodically
by flushing the system.
Note: Yanmar recommends using genuine
Yanmar antifreeze / coolant.

Principal Engine Specifications GENERAL SERVICE INFORMATION
12/05
PRINCIPAL ENGINE SPECIFICATIONS

Engine Model 6SY-STP2 / 6SY655 8SY-STP
Number of Cylinders In-line 6 8 (V8, 90°)
Type Water-cooled, turbocharged
Combustion System Direct injection
Aspiration Turbocharged with intercooler
Bore x Stroke 127 mm x 154 mm (5.0 in. x 6.063 in.)
Displacement 11.7 L (714 cu in.) 15.6 L (952 cu in.)
Firing Order 1-5-3-6-2-4 1-5-4-2-6-3-7-8
Compression Ratio 16:1
Rated output at crankshaft (fuel 40°C [104°F]) +0% / -5%
Continuous output (at 2100 rpm) 405 kW (550 hp) 482 kW (665 hp)
Maximum output (at 2300 rpm) 6SY-STP2: 530 kW (720 hp) 662 kW (900 hp)
6SY655: 481 kW (655 hp)
Mean pressure 1.97 MPa (287.2 psi) 1.84 MPa (266.86 psi)
Idle Speed
High idle 2400 rpm
Low idle 600 rpm
Rotation Direction Counterclockwise (viewed from flywheel)
No. of Valves per Cylinder
Intake 2
Exhaust 2
Turbocharger Single water-cooled Dual water-cooled
Electrical System 2-pole, 24 V
Starter 6.7 kW (9.0 hp)
Charging System 65 A at 24V* 140 A at 24V
Battery Capacity - Recommended 160 Ah
Injection Timing Variable (EMS controlled)
Permissible Value for Exhaust Back Pressure 9.8 kPa (1000 mmAq) 4.9 kPa (500 mmAq)
Cooling System Closed cooling system with heat exchanger
Coolant capacity with coolant recovery 40 L (10.5 gal) 75 L (20 gal)
tank
Thermostats
Engine type and opening temperature Dual - 75°C (167°F)
Charge air cooler type and opening Single - 50°C (122°F)
temperature
Seawater Pump Rubber impeller, gear driven
Capacity 315 L/min at 2300 rpm 300 L/min at 2300 rpm
(83 gpm at 2300 engine rpm) (79 gpm at 2300 engine rpm)
Gear Oil Cooler Restriction 150 mbar (0.03495 psi)

GENERAL SERVICE INFORMATION Principal Engine Specifications
Engine Model 6SY-STP2 / 6SY655 8SY-STP

Lubrication System Totally enclosed, forced lube system
Oil cooler Closed coolant system
Lube oil pressure - Rated speed 300 - 600 kPa (44 - 87 psi)
Lube oil pressure - Idling speed 150 kPa (22 psi)
Lube system capacity (with filters) 23 - 31 L (6 - 8.2 gal)** 32 - 40 L (8.5 - 10.5 gal)**
Crankcase Ventilation Closed, with filter
Engine Size
Height 1038 mm (40.9 in.) 1069 mm (42.1 in.)
Length Overall - 1559 mm (50.9 in.) Overall - 1295 mm (50.9 in.)
Front Bell Housing - 1366 mm Front Bell Housing - 1236 mm
(53.8 in.) (48.6 in.)
Width 867 mm (34.1 in.) 1250 mm (49.2 in.)
Weight 1160 kg (2557 lb) 1650 kg (3638 lb)
* Optional dual 65A alternators available
** Capacity will vary depending on installation angle

Engine Service Standards GENERAL SERVICE INFORMATION
12/05
ENGINE SERVICE STANDARDS

Test and Adjustment Specifications
Inspection Item Specification Reference Page
Intake Valve Clearance 0.45 mm (0.018 in.) See Adjust Valve and
Exhaust Valve Clearance 0.70 mm (0.028 in.) Unit Injector Clearances
on page 5-18
PDE31 Unit Injector Height 66.8 - 67.0 mm See Adjusting Unit
(2.63 - 2.64 in.) Injectors on page 5-19
PDE32 Unit Injector Height 69.8 - 70.0 mm
(2.75 - 2.76 in.)
Fuel Pressure Minimum at 500 rpm 4.5 bar (65 psi) See Measure the Fuel
Minimum at 1900 rpm 5.5 bar (80 psi) Feed Pump Pressure
on page 6-7
Compression 6SY Not available at time of publication
Pressure at Cranking 8SY
Deviation Between Cylinders All Models Not available at time of publication
Oil Pressure Switch Operating Pressure Not available at time of publication
Fuel Pressure Relief Minimum (Hand Pumping) 4.5 bar (65 psi) See Test the Fuel
Valve Pressure Maximum at 1500 rpm 7.5 bar (109 psi) Pressure Relief Valve
on page 6-8
Return Line Tubing 6 mm OD Minimum Internal 35 mm (1.38 in.) See Replace Return
12 mm OD Diameter of Bend 95 mm (3.74 in.) Fuel Line on page 6-15
Cooling System Test All 0.4 - 0.5 bar (5.8 - 7.3 psi) See Pressure Testing
Pressure Cooling System and
Filler Cap Test Pressure All 0.4 - 0.6 bar (5.8 - 8.7 psi) Filler Cap on page 7-7
Thermostat Marking Starts Opening Fully Open See Testing the

6SY 75°C 73 - 77°C 87°C (189°F) Thermostat on page 7-8
(163 - 171°F)
8SY 75°C 73 - 77°C 87°C (189°F)
(163 - 171°F)
Coolant Temperature All Not available at time of publication
Switch

GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts
TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS

Tightening Fasteners Unions
Use the correct amount of torque when tightening Size Straight
Elbow S-Union
the fasteners. Applying excessive torque may Union Gland Nut
damage the fastener or component and not enough M10 x 1.0 10 N·m 8 N·m -
torque may cause a leak or component failure. (88.5 in.-lb) (70.8 in.-lb)*
M12 x 1.5 20 N·m 15 N·m 30 N·m
Flange Bolts and Nuts (177 in.-lb) (133 in.-lb)* (22 ft-lb)
Nominal M14 x 1.5 25 N·m 20 N·m 40 N·m

Coarse Thread (221 in.-lb) (177 in.-lb)* (30 ft-lb)
Diameter
Grade 8.8 or 8 10.9 or 10 M16 x 1.5 30 N·m 25 N·m 50 N·m
(22 ft-lb) (221 in.-lb)* (37 ft-lb)
M5 5.4 N·m (44 in.-lb) 6.7 N·m (55 in.-lb)
M18 x 1.5 30 N·m 25 N·m 60 N·m
M6 8.6 N·m (71 in.-lb) 10.7 N·m (89 in.-lb) (22 ft-lb) (221 in.-lb)* (44 ft-lb)
M8‘ 22 N·m (177 in.-lb) 27 N·m (221 in.-lb) M20 x 2.5 45 N·m 40 N·m -
M10 42 N·m (29 ft-lb) 52 N·m (36 ft-lb) (33 ft-lb) (30 ft-lb)*
M12 77 N·m (52 ft-lb) 95 N·m (64 ft-lb) M22 x 1.5 45 N·m 40 N·m -
(33 ft-lb) (30 ft-lb)*
M14 123 N·m (83 ft-lb) 154 N·m (103 ft-lb)
M24 x 10 - - 70 N·m
(52 ft-lb)
M26 x 1.5 60 N·m 55 N·m -
(44 ft-lb) (41 ft-lb)*
M30 x 2 - - 80 N·m
(59 ft-lb)
* Continue tightening to the correct

position
Hexagon Bolts and Nuts

Nominal
Coarse Thread Fine Thread
Diameter
Grade 8.8 or 8 10.9 or 10 8.8 or 8 10.9 or 10
M4 2.4 N·m (21.2 in.-lb) 3 N·m (26.5 in.-lb) - -
M5 5 N·m (44 in.-lb) 6.2 N·m (55 in.-lb) - -
M6 8 N·m (71 in.-lb) 10 N·m (89 in.-lb) - -
M8‘ 20 N·m (177 in.-lb) 25 N·m (221 in.-lb) 21 N·m (186 in.-lb) 27 N·m (239 in.-lb)
M10 39 N·m (29 ft-lb) 49 N·m (36 ft-lb) 42 N·m (31 ft-lb) 52 N·m (38 ft-lb)

Abbreviations and Symbols GENERAL SERVICE INFORMATION
12/05
ABBREVIATIONS AND JASO Japanese Automobile Standards

Organization
SYMBOLS K kelvin
kg kilogram
Abbreviations kgf/cm² kilogram force per square
centimeter
A ampere
kgf/m kilogram force per meter
AC alternating current
km kilometers
ACEA Association des Constructeurs
kPa kilopascal
Européens d’Automobilies
kW kilowatt
Ah ampere-hour
L liter
API American Petroleum Institute
L/hr liter per hour
ARB Air Resources Board
lb pound
ATDC after top dead center
lbf pound force
BDC bottom dead center
m meter
BTDC before top dead center
mL milliliter
°C degree Celsius
mm millimeter
CARB California Air Resources Board
mmAq millimeter Aqueous (water)
CCA cold cranking amp
MPa megapascal
cfm cubic feet per minute
mV millivolt
cm centimeter
N newton
cm³ cubic centimeter
N·m newton meter
cm³/min cubic centimeter per minute
No. number
cu in. cubic inch
O.D. outside diameter
D diameter
oz ounce
DC direct current
Pa pascal
DI direct injection
PS horsepower (metric)
DVA direct volt adapter
psi pound per square inch
EPA Environmental Protection Agency
qt quart (U.S.)
ESG electronic speed governor
R radius
°F degree Fahrenheit
rpm revolutions per minute
fl oz fluid ounce (U.S.)
SAE Society of Automotive Engineers
fl oz/min fluid ounce (U.S.) per minute
sec. second
ft foot
t short ton 2000 lb
ft-lb foot pound
TBN total base number
ft-lbf/min foot pound force per minute
TDC top dead center
g gram
V volt
gal gallon (U.S.)
VAC volt alternating current
gal/hr gallon (U.S.) per hour
VDC volt direct current
gal/min gallon (U.S.) per minute
W watt
GL gear lubricant
hp horsepower (U.S.) Symbols
hr hour
I.D. inside diameter ° degree
ID identification + plus
IDI indirect injection - minus
in. inch ± plus or minus
in.Aq inches Aqueous (water) Ω ohm
in.Hg inches Mercury μ micro
in.-lb inch pound % percent
J joule

GENERAL SERVICE INFORMATION Unit Conversions
UNIT CONVERSIONS Units of Torque

ft-lb x 1.3558 = N·m
Unit Prefixes ft-lb x 0.1383 = kgf/m
Prefix Symbol Power in.-lb x 0.1130 = N·m
mega M x 1,000,000 in.-lb x 0.0115 = kgf/m
kilo k x 1,000 kgf/m x 7.2330 = ft-lb
centi c x 0.01 kgf/m x 86.8000 = in.-lb
milli m x 0.001 kgf/m x 9.8070 = N·m
micro μ x 0.000001 N·m x 0.7376 = ft-lb
N·m x 8.8510 = in.-lb
Units of Length N·m x 0.1020 = kgf/m
mile x 1.6090 = km Units of Pressure
ft x 0.3050 =m
in. x 2.5400 = cm psi x 0.0689 = bar
in. x 25.4000 = mm psi x 6.8950 = kPa
km x 0.6210 = mile psi x 0.0703 = kg/cm²
m x 3.2810 = ft bar x 14.5030 = psi
cm x 0.3940 = in. bar x 100.0000 = kPa
mm x 0.0394 = in. bar x 29.5300 = inHg (60°F)
kPa x 0.1450 = psi
Units of Volume kPa x 0.0100 = bar
kPa x 0.0102 = kg/cm²
gal (U.S.) x 3.78540 =L
kg/cm² x 98.0700 = psi
qt (U.S.) x 0.94635 =L
kg/cm² x 0.9807 = bar
cu in. x 0.01639 =L
kg/cm² x 14.2200 = kPa
cu in. x 16.38700 = mL
in.Hg (60°) x 0.0333 = bar
fl oz (U.S.) x 0.02957 =L
in.Hg (60°) x 3.3770 = kPa
fl oz (U.S.) x 29.57000 = mL
in.Hg (60°) x 0.0344 = kg/cm²
cm³ x 1.00000 = mL
mmAq x 0.0394 = in.Aq
cm³ x 0.03382 = fl oz (U.S.)
Units of Mass Units of Power

hp (metric x 0.9863201 = hp SAE
lb x 0.45360 = kg
or PS)
oz x 28.35000 =g
hp (metric x 0.7354988 = kW
kg x 2.20500 = lb
or PS)
g x 0.03527 = oz
hp SAE x 1.0138697 = hp (metric or PS)
Units of Force hp SAE x 0.7456999 = kW
kW x 1.3596216 = hp (metric or PS)
lbf x 4.4480 =N kW x 1.3410221 = hp SAE
lbf x 0.4536 = kgf
N x 0.2248 = lbf Units of Temperature
N x 0.1020 = kgf
°F = (1.8 x °C) + 32
kgf x 2.2050 = lbf
°C = 0.556 x (°F - 32)
kgf x 9.8070 =N

Section 4
PERIODIC
MAINTENANCE
Page
Introduction...................................................................................... 4-3
The Importance of Periodic Maintenance.................................. 4-3
Performing Periodic Maintenance ............................................. 4-3
Yanmar Replacement Parts ...................................................... 4-3
Required EPA Maintenance - USA Only ................................... 4-3
EPA Installation Requirements - USA Only............................... 4-3
Periodic Maintenance Schedule...................................................... 4-4
Periodic Maintenance Procedures .................................................. 4-7
After Initial 50 Hours of Operation ............................................. 4-7
Every 50 Hours of Operation ..................................................... 4-7
Every 250 Hours of Operation ................................................... 4-8
Every 500 Hours of Operation ................................................... 4-8
Every 1000 Hours of Operation ................................................. 4-9
Every 2000 Hours of Operation ................................................. 4-9
EPA Requirements........................................................................ 4-10
Conditions to Ensure Compliance with EPA Emission
Standards ................................................................................ 4-10
Inspection and Maintenance.................................................... 4-10

PERIODIC MAINTENANCE

Introduction PERIODIC MAINTENANCE
12/05
INTRODUCTION EPA Installation Requirements - USA

This section of the Service Manual describes the Only
procedures for proper care and maintenance of the The following are the installation requirements for
engine. the EPA. Unless these requirements are met, the
exhaust gas emissions will not be within the limits
The Importance of Periodic specified by the EPA.
Maintenance
See Conditions to Ensure Compliance with EPA
Engine deterioration and wear occurs in proportion Emission Standards on page 4-10 for operating
to length of time the engine has been in service and conditions.
the conditions the engine is subject to during
operation. Periodic maintenance prevents
unexpected downtime, reduces the number of
accidents due to poor machine performance and
helps extend the life of the engine.
Performing Periodic Maintenance

Perform periodic maintenance procedures in an
open, level area free from traffic. If possible,
perform the procedures indoors to prevent
environmental conditions such as rain, wind or
snow from damaging the engine. WARNING!
NEVER block windows, vents or other means of
ventilation if the engine is operating in an
enclosed area. All internal combustion engines
create carbon monoxide gas during operation.
Accumulation of this gas within an enclosure
could cause illness or even death.
Yanmar Replacement Parts

Yanmar recommends that you use genuine Yanmar
parts when replacement parts are needed.
Genuine replacement parts help ensure long
engine life.
Required EPA Maintenance - USA

Only
To maintain optimum engine performance and
compliance with the Environmental Protection
Agency (EPA) Regulations, it is essential that you
follow the Periodic Maintenance Schedule on
page 4-4 and Periodic Maintenance Procedures on
page 4-7.

PERIODIC MAINTENANCE Periodic Maintenance Schedule
PERIODIC MAINTENANCE SCHEDULE

Daily and periodic maintenance is important to keep the engine in good operating condition. The following
is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary
depending on engine application, loads, diesel fuel and engine oil used and are hard to establish
definitively. The following should be treated only as a general guideline.
c: Check or Clean : Replace

Periodic Maintenance Interval
Every Every 250 Every 500 Every 1000 Every 2000
System Item 50 hours or hours or one hours or 2 hours or 4 hours or 8
Daily one month year years years years
whichever whichever whichever whichever whichever
comes first comes first comes first comes first comes first
Whole Visual inspection of engine c
exterior
Fuel System Check the fuel level and c
refill
Drain the fuel tank c
Drain the fuel filter and the c
fuel / water separator (Initial 50)
Replace the fuel filter
element (Initial 50)
Check and adjust unit c* c*
injector / rocker arms (Initial 250)
Overhaul and check fuel c
feed pump
Replace rubber fuel hoses Replace every 2 years or every 2000 hours, whichever comes first.
Lubricating Check the engine oil level c
System
Change the engine oil
(Initial 50)
Replace the engine oil filter
element (Initial 50)
Replace the closed
crankcase ventilation filter
Clean the centrifugal c c
engine oil cleaner (Initial 50)
Clean engine oil cooler c
Air Intake and Clean or replace the air c
Exhaust intake filter element
System
Clean the exhaust / water c
mixing elbow
Clean the turbocharger c*
Clean the charge air cooler c

Periodic Maintenance Schedule PERIODIC MAINTENANCE
12/05
c: Check or Clean : Replace

Periodic Maintenance Interval
Every Every 250 Every 500 Every 1000 Every 2000
System Item 50 hours or hours or one hours or 2 hours or 4 hours or 8
Daily one month year years years years
whichever whichever whichever whichever whichever
comes first comes first comes first comes first comes first
Cooling Check the seawater outlet c
System During
Operation
Check the coolant level c
Check or replace seawater c
pump impeller
Change the engine coolant Every year
When Long Life Coolant is used, replace every two years. See Drain, Flush and Fill the Engine
with Engine Coolant on page 7-8.
Clean and check the c
seawater passages
Clean the seawater and c
engine closed cooling
system
Check or replace the
anodes
Clean the closed cooling c
system (Internal)
Electrical Check the alarm indicators c
System
Check the battery charge c
Clean the battery c
Check the battery c
electrolyte level
Adjust the tension of the c c
alternator belt or replace (Initial 50)
belt
Check the wiring c c
connectors
Engine Check for leakage of fuel, c
Cylinder Head engine oil and engine After starting
and Block coolant
Tighten all major nuts and c
bolts
Adjust intake / exhaust c c
valve clearance (Initial 250)
Miscellaneous Check the electronic c c
Items control system (EMS) (Initial 50)
operation
Adjust the propeller shaft c c
alignment (Initial 50)
Check / replace flexible c
engine mounts
* Required to conform to US EPA regulations. See EPA Requirements on page 4-10.
Note: The above procedures are considered normal maintenance and are performed at the owner’s
expense.

PERIODIC MAINTENANCE Periodic Maintenance Schedule
Inspection and Maintenance of EPA Emission-Related Parts

Parts Interval
Clean fuel injection nozzle 1500 hours
Check fuel injection nozzle adjustment
Check fuel injection pump adjustment
Check turbocharger adjustment 3000 hours
Check electronic engine control unit (ECU) and its associated
sensors and actuators

Periodic Maintenance Procedures PERIODIC MAINTENANCE
12/05
PERIODIC MAINTENANCE
PROCEDURES Every 50 Hours of Operation
After you complete the initial 50 hour maintenance

After Initial 50 Hours of Operation procedures, perform the following procedures every
50 hours thereafter.
Perform the following maintenance after the initial
50 hours of operation. • Check Battery Electrolyte Level
• Drain the Fuel Filter and Fuel / Water

Separator
• Replace the Fuel Filter Element
• Change the Engine Oil and Replace the
Engine Oil Filter
• Clean the Centrifugal Oil Cleaner
• Check and Adjust Alternator Belt
• Check Electronic Management System (EMS)
Operation
• Adjust Propeller Shaft Alignment

PERIODIC MAINTENANCE Periodic Maintenance Procedures
Every 250 Hours of Operation Every 500 Hours of Operation
Perform the following maintenance every 250 hours Perform the following maintenance every 500 hours
of operation or 1 year, whichever comes first. of operation or 2 years, whichever comes first.
• Adjust Intake / Exhaust Valve Clearance • Replace Seawater Pump Impeller
(Initial 250)
• Check Alternator Belt Tension
• Adjust Unit Injectors (Initial 250)
• Adjust the Propeller Shaft Alignment
• Drain the Fuel Tank
• Replace the Fuel Filter Element
• Change the Engine Oil
• Replace the Engine Oil Filter Element
• Replace the Closed Crankcase Ventilation
Filter
• Clean the Centrifugal Engine Oil Cleaner
• Check the Seawater Pump Impeller
• Replace the Anodes
• Clean the Closed Cooling System (Internal)
• Clean the Air Intake Filter Element
• Clean the Exhaust / Water Mixing Elbow
• Clean the Turbocharger
• Flush the Charge Air Cooler
• Check the Wiring Connectors
• Tighten All Major Nuts and Bolts
• Check or Replace the Flexible Engine Mounts
• Drain, Flush and Refill the Engine Coolant

Periodic Maintenance Procedures PERIODIC MAINTENANCE
12/05
Every 1000 Hours of Operation Every 2000 Hours of Operation
Perform the following maintenance every 1000 Perform the following maintenance every 2000
hours of operation or 4 years, whichever comes hours of operation or 8 years, whichever comes
first. first.
• Adjust Unit Injectors / Rocker Arms • Overhaul and Check Fuel Feed Pump
• Clean and Check the Seawater Passages • Replace Rubber Fuel Hoses
• Replace Alternator Belt • Clean Engine Oil Cooler
• Adjust Intake / Exhaust Valve Clearance • Clean Seawater and Engine Coolant System
• Replace the Flexible Engine Mounts • Check the Wiring Connectors

PERIODIC MAINTENANCE EPA Requirements
EPA REQUIREMENTS Inspection and Maintenance

The EPA emission regulation is applicable only in See Inspection and Maintenance of EPA
USA. Emission-Related Parts on page 4-6 for the EPA
emission-related parts. Inspection and
Conditions to Ensure Compliance maintenance procedures not shown in the
with EPA Emission Standards Inspection and Maintenance of EPA
Emission-Related Parts section are covered in
This product is an EPA-approved engine. Periodic Maintenance Schedule on page 4-4.
The following are the conditions that must be met in This maintenance must be performed to keep the
order to ensure that the emissions during operation emission values of your engine in the standard
meet the EPA standards. Be sure to follow these: values during the warranty period. The warranty
The operating conditions should be as follows: period is determined by the age of the engine or the
number of hours of operation.
• Ambient temperature: -20 to 40°C (-4 to 104°F)
• Relative humidity: 80% or lower
• Permissible value for intake negative pressure:
3.9 kPa (400 mmAq) or lower
• Permissible value for exhaust back pressure:
6SY: 9.8 kPa (1000 mmAq) or lower
8SY: 4.9 kPa (500 mmAq) or lower
The fuel and lubricating oil used should be as
follows:
• Diesel fuel oil: ASTM D975 No. 1-D or No. 2-D, or
equivalent (minimum of cetane No. 45)
• Lubricating Oil: ACEA Class E3, E4 or E5; Type
API, Class CH-4, CI-4
Be sure to perform inspections as outlined in
Periodic Maintenance Procedures on page 4-7 and
keep a record of the results.
Pay particular attention to these important points:
• Replacing the engine oil
• Replacing the lube oil filter
• Replacing the fuel filter
• Cleaning the intake silencer (air cleaner)
Note: Inspections are divided into two sections
in accordance with who is responsible for
performing the inspection: the user or the
maker.

Section 5
ENGINE
Page
Introduction...................................................................................... 5-4
Principal Engine Specifications ................................................. 5-4
Adjustment Specifications ......................................................... 5-4
Cylinder Head Specifications..................................................... 5-5
Camshaft and Timing Gear Train Specifications ....................... 5-6
Crankshaft and Pistons Specifications ...................................... 5-7
Special Torque Chart ...................................................................... 5-9
Special Service Tools.................................................................... 5-11
Measuring Instruments.................................................................. 5-16
Tests and Adjustments.................................................................. 5-18
Adjust Valve and Unit Injector Clearances .............................. 5-18
Repair............................................................................................ 5-21
Cylinder Head................................................................................ 5-22
Cylinder Head Components .................................................... 5-22
General Guidelines.................................................................. 5-23
Remove and Install Rocker Covers ......................................... 5-23
Remove the Cylinder Head ..................................................... 5-26
Disassemble the Cylinder Head .............................................. 5-27
Clean the Cylinder Head Components .................................... 5-27
Inspect the Cylinder Head Components.................................. 5-27
Replace the Valve Stem Seals ................................................ 5-29
Replace the Valve Seat ........................................................... 5-29
Machine the Valves ................................................................. 5-30
Machine the Valve Seat Inserts............................................... 5-30
Replace the Valve Guides ....................................................... 5-33
Replace the Unit Injector Sleeves ........................................... 5-33
Reassemble the Cylinder Head............................................... 5-34
Install the Cylinder Head ......................................................... 5-34

ENGINE
Pistons and Cylinder Liners ........................................................... 5-36
Remove and Disassemble Piston and Connecting Rod........... 5-37
Inspect the Connecting Rods ................................................... 5-38
Replace the Wrist Pin Bushing................................................. 5-40
Inspect the Pistons and Piston Rings....................................... 5-41
Assemble the Piston and Connecting Rod............................... 5-41
Remove the Cylinder Liners ..................................................... 5-42
Measure the Cylinder Liner Height........................................... 5-44
Install the Cylinder Liners ......................................................... 5-44
Install the Piston and Connecting Rod ..................................... 5-45
Flywheel and Flywheel Housing..................................................... 5-48
Flywheel Housing Components - 6SY Engines........................ 5-48
Flywheel Housing Components - 8SY Engines........................ 5-50
Remove the Flywheel............................................................... 5-51
Flywheel Inspection and Repair ............................................... 5-52
Replace the Rear Crankshaft Seal........................................... 5-52
Remove the Flywheel Housing ................................................ 5-53
Install the Flywheel Housing..................................................... 5-53
Install the Flywheel................................................................... 5-54
Timing Gear Train .......................................................................... 5-56
6SY Components ..................................................................... 5-56
8SY Components ..................................................................... 5-58
Check the Camshaft Timing ..................................................... 5-60
Remove the Front Gear Housing - 8SY ................................... 5-60
Install the Front Gear Housing - 8SY ....................................... 5-62
Intermediate Gear .................................................................... 5-62
Camshaft Gear ......................................................................... 5-67
Crankshaft Gear ....................................................................... 5-69
Remove the Camshaft.............................................................. 5-70
Replace the Camshaft Bearings - 6SY..................................... 5-71
Replace the Camshaft Bearings - 8SY..................................... 5-75
Install the Camshaft.................................................................. 5-78
Cylinder Block and Crankshaft ....................................................... 5-82
Remove the Crankshaft............................................................ 5-84
Measure the Oil Clearance....................................................... 5-85
Inspect the Crankshaft ............................................................. 5-86
Recondition the Crankshaft ...................................................... 5-87
Inspect the Cylinder Block........................................................ 5-87
Install Crankshaft...................................................................... 5-88
Replace the Front Crankshaft Seal .......................................... 5-90
Exhaust Manifold............................................................................ 5-91
Replacing Gaskets ................................................................... 5-91
Lifting the Engine ........................................................................... 5-92
Attaching Engine to Repair Stand .................................................. 5-93

Safety Precautions ENGINE
12/05
SAFETY PRECAUTIONS
NEVER attempt to adjust the low or high idle speed
limit screw. This may impair the safety and
Avoid serious injury or death. performance of the engine and shorten its life. If
ALWAYS ensure that all connections adjustment is ever required, see your authorized
are tightened to specifications after Yanmar marine dealer or distributor.
repair is made to the exhaust system.
All internal combustion engines
create carbon monoxide gas during operation and
special precautions are required to avoid carbon
monoxide poisoning.

ENGINE Introduction
INTRODUCTION
This section of the Service Manual describes the
disassembly, inspection, and reassembly of the
6SY and 8SY engines.
Principal Engine Specifications

See Principal Engine Specifications on page 3-15.
Adjustment Specifications
Adjustments
Inspection Item Specification
Intake Valve Clearance 0.45 mm (0.018 in.)
Exhaust Valve Clearance 0.70 mm (0.028 in.)
PDE31 Unit Injector Spring Height 66.8 - 67.0 mm
(2.63 - 2.64 in.)
PDE32 Unit Injector Spring Height 69.8 -70.0 mm
(2.75 - 2.76 in.)

Introduction ENGINE
12/05
Cylinder Head Specifications

Cylinder Head and Valves
Reference
Inspection Item Standard Oversize
Page
Valve Recession Intake 0.75 - 1.8 mm (0.030 - 0.071 in.) See Valve
Exhaust 0.66 - 1.8 mm (0.026 - 0.071 in.) Recession
on
page 5-27.
Valve Face Angle Intake 19.5° See
Exhaust 44.5° Inspection of
Intake and
Valve Margin (Minimum) Intake 2.6 mm (0.102 in.) Exhaust
Exhaust 1.8 mm (0.071 in.) Valves on
page 5-27.
Valve Seat Seat Angle Intake 20.0 - 20.5°
Exhaust 45.0 - 45.5°
Seat Undercut Angle Intake 60°
Exhaust 60°
Seat Overcut Angle Intake 60°
Exhaust NA
Seat Contact Width Intake 1.9 - 2.6 mm (0.075 - 0.102 in.)
Exhaust 1.8 - 2.6 mm (0.071 - 0.102 in.)
Cutting Tool Setting - Intake 39.3 - 40.3 mm
Diameter (1.547 - 1.587 in.)
Exhaust 37.3 - 38.3 mm
(1.472 - 1.512 in.)
Replacement Valve Outside Diameter Intake 46.054 - 46.065 mm 46.254 - 46.265 mm
Seat Insert (1.8131 - 1.8136 in.) (1.8210 - 1.8215 in.)
Exhaust 44.081 - 44.092 mm 44.281 - 44.292 mm
(1.7355 - 1.7359 in.) (1.7433 - 1.7438 in.)
Bore Diameter in Intake 46.000 - 46.016 mm 46.200 - 46.216 mm
Cylinder Head (1.8110 - 1.8116 in.) (1.8189 - 1.8195 in.)
Exhaust 44.000 - 44.016 mm 44.200 - 44.216 mm
(1.7323 - 1.7329 in.) (1.7402 - 1.7408 in.)
Bore Depth Intake 11.25 - 11.35 mm (0.443 - 0.447 in.)
Exhaust

ENGINE Introduction
Camshaft and Timing Gear Train Specifications

Camshaft
Inspection Item Standard Reference Page
End Play 0.10 - 0.25 mm See Remove the
(0.004 - 0.010 in.) Camshaft on page
5-70.
Timing - 6SY Intake Exhaust See Check the
0.37 - 1.47 mm 0.16 - 1.16 mm Camshaft Timing
0.015 - 0.058 in 0.006 - 0.046 in on page 5-60
Intermediate Gear and Bushing

Reference
Inspection Item Standard Limit
Page
End Play - 0.238 mm See
(0.009 in.) Intermediate
Gear on
page 5-62
Timing Gear Backlash

Reference
Inspection Item 6SY 8SY
Page
Camshaft-to-Intermediate Gear 0.03 - 0.15 mm * -
(0.002 - 0.006 in.)
* Not available at time of publication

Introduction ENGINE
12/05
Crankshaft and Pistons Specifications

Crankshaft
6SY Reference
Inspection Item
8SY Page
Connecting Rod Journals Standard Diameter 86.978 - 87.000 mm (3.4247 - 3.4252 in.) See Inspect
Undersize 1 86.728 - 86.750 mm (3.4247- 3.4153 in.) the
Diameter Crankshaft
on page 5-86
Undersize 2 86.478 - 86.500 mm (3.4046 - 3.4055 in.)
Diameter
Undersize 3 86.228 - 86.250 mm (3.3948 - 3.3957 in.)
Diameter
Undersize 4 85.978 - 86.000 mm (3.3850 - 3.3858 in.)
Diameter
Hole Recess Radius 4.8 - 5.2 mm (0.189 - 0.205 in.)
Surface Quality 0.25 Ra
Width, Max. 56.05 mm (2.207 in.)
Oil Clearance 0.051 - 0.114 mm (0.0020 - 0.0045 in.)
Main Bearing Journals Standard Diameter 107.978 - 108.000 mm (4.2511 - 4.2520 in.)
Undersize 1 107.728 - 107.750 mm (4.2412 - 4.2421 in.)
Diameter
Undersize 2 107.428 - 107.450 mm (4.2294 - 4.2303 in.)
Diameter
Undersize 3 107.228 - 107.250 mm (4.2216 - 4.2224 in.)
Diameter
Undersize 4 106.978 - 107.000 mm (4.2117 - 4.2126 in.)
Diameter
Oil Hole Radius 4.75 - 4.85 mm (0.187 - 0.191 in.)
Surface Quality 0.25 Ra
Main Bearing Bore Standard Diameter 112.200 - 112.222 mm (4.4173 - 4.4182 in.) See Inspect
Out-of-Round (Max.) 0.016 mm (0.0006 in.) the Cylinder
Block on
page 5-87
Thrust Bearing
Reference
Page
Thrust Bearing Standard Thickness 3.37 - 3.43 mm (0.133 - 0.135 in.) See Inspect
Oversize 1 Thickness 3.45 - 3.51 mm (0.136 - 0.138 in.) the
Crankshaft
Oversize 2 Thickness 3.50 - 3.56 mm (0.138 - 0.140 in.) on page 5-86
Oversize 3 Thickness 3.63 - 3.69 mm (0.143 - 0.145 in.)
Oversize 4 Thickness 3.88 - 3.94 mm (0.153 - 0.155 in.)
End Play 0.138 - 0.380 mm (0.0054 - 0.0149 in.)

ENGINE Introduction
Cylinder Liner
Reference
Page
Cylinder Liner Protrusion 0.15 - 0.30 mm See Measure
(0.006 - 0.012 in.) the Cylinder
Protrusion Variation on One Liner (Max.) 0.02 mm Liner
(0.0008 in.) Height on
page 5-44
Available Shims 0.20, 0.25, 0.30, 0.40, 0.50, 0.75 mm
Connecting Rod
Reference
Page
Wrist Pin Bushing ID 54.030 - 54.043 mm - See Inspect
(2.1272 - 2.1277 in.) the Pistons
Twist - 6SY - 0.10 mm (0.004 in.) and Piston
Rings on
Bend - 6SY - page 5-41
Twist - 8SY 0.05 mm (0.002 in.)
Bend - 8SY
Bend - “S” Shape - 6SY 0.60 mm (0.024 in.)
Bend - “S” Shape - 8SY 4.5 mm (0.177 in.)
Piston Ring
Reference
Page
Top Ring End Gap 0.35 - 0.60 mm - See Inspect the
(0.014 - 0.024 in.) Pistons and
Second Ring Side Clearance - 0.25 mm (0.010 in.) Piston Rings on
page 5-41
End Gap 0.45 - 0.65 mm -
(0.018 - 0.026 in.)
Oil Ring Side Clearance - 0.25 mm (0.010 in.)
End Gap 0.40 - 0.65 mm -
(0.016 - 0.026 in.)

Special Torque Chart ENGINE
12/05
SPECIAL TORQUE CHART
Lubricating Oil
Application (Thread
Component Torque Reference Page
Portion and Seat
Surface)
Rocker Arm Adjusting Screw Lock Nut 39 N·m (29 ft-lb) - See Adjust Valve and
Unit Injector
Clearances on
page 5-18
Rocker Arm Shaft Support Bracket Bolt 105 N·m (77 ft-lb) Not Applied See Install the Cylinder
Rocker Arm Shaft Bolt 105 N·m (77 ft-lb) Not Applied Head on page 5-34
Cylinder Head Bolt First tightening 60 N·m (44 ft-lb) Applied

Second tightening 150 N·m (110 ft-lb)
Third tightening 250 N·m (184 ft-lb)
Fourth tightening Plus 90°
Unit Injector Fork Clamp Bolt (torque-turn) 20 N·m (133 in.-lb) plus Not Applied
75°
Injector Electrical Terminal Screw 2 N·m Not Applied
(283 in.-oz)
Rocker Cover Bolt (Upper and Lower Cover) 26 N·m (230 in.-lb) Not Applied
Exhaust Manifold Bolt 6SY 59 N·m (44 ft-lb) Not Applied
8SY 63 N·m (46 ft-lb) Not Applied
Turbocharger Bolt 6SY 50 N·m (37 ft-lb) Not Applied
Lower Intake Manifold 26 N·m (230 in.-lb) Not Applied
Charge Air Cooler Bolt 26 N·m (230 in.-lb) Not Applied
Upper Intake Manifold 6SY 26 N·m (230 in.-lb)
Fuel Delivery Union Nut 20 N·m (133 in.-lb) Not Applied
Fuel Manifold Mounting Bolt 26 N·m (230 in.-lb) Not Applied
Fuel Return Banjo Bolt 11 N·m (97 in.-lb) Not Applied
Flywheel Mounting Bolt (torque-turn) 130 N·m (96 ft-lb) plus Not Applied See Install the
90° Flywheel on page 5-54
Flywheel Housing Bolt M10 50 N·m (37 ft-lb) Not Applied See Install the
M12 90 N·m (66 ft-lb) Not Applied Flywheel Housing on
page 5-53
Timing Gear Plate Bolt - 6SY 63 N·m (46 ft-lb) Not Applied See Install the
Tappet Mounting Bolt 32 N·m (24 ft-lb) Not Applied Camshaft on
page 5-78
Intermediate Gear Bolt (torque-turn) 50 N·m (37 ft-lb) plus Not Applied
60°
Camshaft Gear Bolt 63 N·m (46 ft-lb) Not Applied

ENGINE Special Torque Chart
Lubricating Oil
Application (Thread
Portion and Seat
Surface)
Oil Sump Bolt 30 N·m (22 ft-lb) Not Applied See Install
Oil Pump Mounting Bolt 26 N·m (19 ft-lb) Applied Crankshaft on
page 5-88
Piston Cooling Nozzle Bolt 23 N·m (17 ft-lb) Applied
Connecting Rod Bolt 6SY 20 N·m (177 in.-lb) plus Applied
(torque-turn) 90°
8SY 50 N·m (37 ft-lb) plus Applied
90°
Main Bearing Cap Bolt 6SY 50 N·m (37 ft-lb) plus Applied
(torque-turn) 90°
8SY 90 N·m (66 ft-lb) plus
90°
Main Bearing Side Bolts 8SY 180 N·m (133 ft-lb)
Crankshaft Driver Bolt 135 N·m (100 ft-lb) Not Applied
Crankshaft Damper Bolt 6SY 110 N·m (81 ft-lb) Not Applied
Belt Pulley Bolt 6SY 110 N·m (81 ft-lb) Not Applied

Special Service Tools E N G IN E
12/05
SPECIAL SERVICE TOOLS

Note: The tool numbers used in this section are either Yanmar or Scania part numbers. Yanmar part
numbers are referred to as Yanmar Part No. Scania part numbers are referred to as OEM Part No.
Tools not having part numbers must be obtained locally.
No. Tool Name Applicable Model and Tool Size Illustration

1 Valve Guide Tool OEM Part No. 99 383
(For Removing
Valve Guides)
0002668
2 Valve Guide Tool OEM Part No. 99 382

(For Installing
Valve Guides)
0002669
3 Guide (For OEM Part No. 99 394

Removal and
Installation of
Injector Sleeves.
Use with 588 221
Pilot Tap)
0002670
4 Drift (For OEM Part No. 99 384

Installing Valve
Seats)
0002664
5 Driver (For Use OEM Part No. 99 385

with 99 384 Drift)
0002665
6 Pilot Tap (For OEM Part No. 588 221

Removing
Injector Sleeves)
0002667

ENGINE Special Service Tools

7 Flywheel Turning OEM Part No. 99 309
Tool
0002660
8 Slide Hammer OEM Part No. 87 596
0002655
9 Valve Spring OEM Part No. 99 322

Compressor
0002662
10 Valve Stem Seal OEM Part No. 99 323

Installer
0002663
11 Valve Seat Cutter OEM Part No. 587 277
0002671
12 Unit Injector OEM Part No. 99 414 - PDE31

Adjustment Tool OEM Part No. 99 442 - PDE32
0002672

Special Service Tools ENGINE
12/05

13 Hydraulic OEM Part No. 99 003
Cylinder (For
Removing and
Installing
Camshaft
Bearings)
14 Air-Operated OEM Part No. 99 004
Hydraulic Pump
(For Removing
and Installing
Camshaft
Bearings)
15 Camshaft OEM Part No. 99 373
Bearing
Replacement (3)
Tool (For
Removing and
(1)
Installing
(2)
Camshaft
Bearings - 6SY)
0002343A
16 Bearing Drift (For OEM Part No. 99 516

Removing and
Installing
Camshaft
Bearings - 8SY)
17 Socket (For OEM Part No. 99 517

Removing and
Installing
Camshaft
Bearings - 8SY)
18 Bar (For OEM Part No. 99 518

Removing and
Installing
Camshaft
Bearings - 8SY)
19 Spacer (For OEM Part No. 99 519
Removing and
Installing
Camshaft
Bearings - 8SY)

ENGINE Special Service Tools

20 Flex-Hone Obtain Locally
(For Preparing
Cylinder Walls)
0000823
21 Piston Ring Obtain Locally

Compressor (For
Installing Piston)
0000824
22 Piston Ring Tool Obtain Locally

(For Removing/
Installing Piston
Rings)
0000825
23 Lifting Eyes OEM Part No. 99 398

(Used to Lift
Engine)
24 Lifting Eyes OEM Part No. 1 360 442

(Used to Lift
Engine)
25 Lifting Eyes OEM Part No. 1 512 730

(Used to Lift
Engine)
26 Lifting Chain OEM Part No. 98 094

(Used to Lift
Engine)

Special Service Tools ENGINE
12/05

27 Lever Block OEM Part No. 587 308
(Used to Lift
Engine)

ENGINE Measuring Instruments
MEASURING INSTRUMENTS
No. Instrument Name Application Illustration

1 Dial Indicator Measure shaft bend and end play
0000831
2 Test Indicator Measurements of narrow or deep portions that

cannot be measured by dial indicator
0000832
3 Magnetic Stand For holding the dial indicator when measuring
0000833
4 Micrometer For measuring the outside diameters of

crankshaft, pistons, piston pins, etc.
0000834
5 Cylinder Bore Gauge For measuring the inside diameters of cylinder

liners, bearing bores, etc.
0000835
6 Calipers For measuring outside diameters, depth,

thickness and width
0000836
7 Depth Micrometer For measuring valve recession
0000837

Measuring Instruments ENGINE
12/05

8 Square For measuring valve spring inclination and
straightness of parts
0000838
9 Torque Wrench For tightening nuts and bolts to the specified

torque
0000840
10 Feeler Gauge For measuring piston ring gaps, piston ring

clearance, fuel injector adjustment clearance,
and valve adjustment clearance
0000841

ENGINE Tests and Adjustments
TESTS AND ADJUSTMENTS

Adjust Valve and Unit Injector Clearances
Note: Check and adjust the valve clearance and unit injector adjustment at the same time with the engine
cold.
Order of Adjustment - 6SY
Adjustment Item Adjust Cylinder Number
Intake and Exhaust Valves 1 5 3 6 2 4
Injector Rocker Arm 5 3 6 2 4 1
Order of Adjustment - 8SY

Adjust Injector
Mark on Flywheel Valve Overlap on Adjust Intake Valve Adjust Exhaust Valve
Rocker Arm on
(Degrees) Cylinder on Cylinder on Cylinder
Cylinder
TDC Down (0°) 6 4 and 5 7 and 8 4 and 5
TDC Up (180°) 7 2 and 6 1 and 5 2 and 6
TDC Down (360°) 1 3 and 7 2 and 4 3 and 7
TDC Up (540°) 4 1 and 8 3 and 6 1 and 8
Figure 5-1 Figure 5-2
(1)
0002270
1. Clean the rocker covers and surrounding area. 3. Turn the flywheel using the flywheel turning tool
2. Remove the upper rocker covers (Figure 5-1). (OEM Part No. 99 309) (Figure 5-2, (1)) until
No. 1 piston is at TDC of the compression
stroke. The rocker arms for No. 1 cylinder will
be loose and the valves for No. 6 cylinder will be
in overlap (both rocker arms under tension).
4. Refer to the appropriate chart for the order of
adjustment. See Order of Adjustment - 6SY on
page 5-18 or Order of Adjustment - 8SY on
page 5-18.
5. Identify the model of unit injector to be adjusted.
See Identifying Unit Injector on page 5-19.

Tests and Adjustments ENGINE
12/05
6. Check and adjust the clearance of the Adjusting Unit Injectors

appropriate valves using a feeler gauge. Note: The PDE31 unit injector is adjusted using
Note: The intake valves are actuated by the the setting tool (OEM Part No. 99 414) or
short rocker arms and the exhaust valves a digital sliding caliper. The PDE32 unit
by the long rocker arms. Make sure the injector is adjusted using the setting tool
valve bridge is resting correctly against (OEM Part No. 99 442) or a digital sliding
the valves. caliper.
7. Check and adjust unit injector of the Identifying Unit Injector
appropriate cylinder before rotating the Figure 5-3
crankshaft. Unit injectors can be adjusted using (1)

a special tool or a digital sliding caliper. See
Adjusting Unit Injectors on page 5-19.
CAUTION! Use care when adjusting the unit
injector if the dimension is outside the
specification. The spring is under
considerable tension and may cause
personal injury if it is unexpectedly
released.
8. Mark the rocker arms with a permanent marker
to identify the rocker arms that have been
adjusted.
9. Rotate the flywheel and adjust the valves and
unit injector for the next cylinder(s).
• 6SY: Rotate the flywheel 120° (1/3 turn) and
0002262
adjust the next cylinder.
Figure 5-3
• 8SY: Rotate the flywheel 180° (1/2 turn) and
adjust the next cylinders. Measure spring diameter (Figure 5-3, (B)) to
identify the injector.
Repeat for the remaining cylinders per the order
of adjustment tables. See Order of Adjustment - Unit Injector Identification
6SY on page 5-18 or Order of Adjustment - 8SY
Inspection Item PDE31 PDE32
on page 5-18.
Injector Spring 36.5 mm 38.8 mm
10. Install the upper rocker covers. Ensure the Diameter (B) (1.44 in.) (1.53 in.)
gasket is in good condition and in place.
Tighten bolts to 26 N·m (230 in.-lb).
Specifications
Inspection Item Intake Exhaust
0.45 mm 0.70 mm
Valve Clearance
(0.018 in.) (0.028 in.)

ENGINE Tests and Adjustments
Digital Caliper Method:

Figure 5-4
Note: Use this method if the appropriate setting

tool is not available.
1. Loosen the adjusting screw locknut. CAUTION!
Use care when adjusting the unit injector if
the dimension is outside the specification. (1)
The spring is under considerable tension
and may cause personal injury if it is
released unexpectedly.
2. Carefully turn the adjusting screw (Figure
5-3, (1)) while measuring the spring height
(Figure 5-3, (A)) between plane (Figure
5-3, (a)) and the top of the valve spring retainer Figure 5-4
using a digital sliding caliper. 2. Position the appropriate setting tool (Figure
3. Tighten the locknut to specification. 5-4, (1)) with the metal plate around the injector
spring.
Specifications Figure 5-5
Inspection Item PDE31 PDE32 (3)

Spring Height (A) 66.8 - 67 mm 69.8 - 70 mm
(2.63 - 2.64 in.) (2.75 - 2.76 in.)
Adjustment Screw 39 N·m (29 ft-lb)
Locknut Torque
Special Tool Method:

NOTICE: Adjust the spring roughly using a sliding (1)
caliper (see Digital Caliper Method: on page 5-20),
then perform fine adjustment using the special tool.
Failure to do so may result in the unit injector
assuming an incorrect position, which will result in (2)
poor performance and possible breakdown.
(2)
1. Select the correct setting tool for the unit
injector being adjusted. Use OEM Part No.
99 414 to adjust PDE31 or OEM Part No.
99 442 to adjust PDE32.
0002266
Figure 5-5

Repair ENGINE
12/05
3. Carefully turn the adjusting screw (Figure REPAIR

5-5, (3)) while simultaneously using a finger to
sense the position of the small piston (Figure If the engine is to be completely disassembled,
5-5, (2)). Adjustment is correct when the piston perform the following preliminary steps:
is flush with the flat upper surface (Figure 1. Disconnect battery cables at the battery. Always
5-5, (1)) of the tool. disconnect negative (-) battery cable first.
4. Tighten the adjusting screw locknut to 39 N·m 2. Close all valves in the fuel supply system.
(29 ft-lb).
3. Remove throttle cable, electrical connections,
intake and exhaust system connections, and
fuel supply lines from engine. Cap or plug all
open fuel connections.
4. Drain engine coolant from cylinder block.
5. Remove engine from boat. See Lifting the
Engine on page 5-92. Mount engine to a
suitable engine repair stand having adequate
weight capacity. DANGER! NEVER stand
under a hoisted engine. If the hoist
mechanism fails, the engine will fall on you,
causing death or serious injury.
6. Cap or plug all openings to prevent
contamination.
7. Remove starter motor and alternator.
8. Clean engine by washing with solvent, air or
steam cleaning. Carefully operate cleaning
equipment so as to prevent any foreign matter
or fluids from entering engine or any fuel
system or electrical components remaining on
the engine.
9. Remove cooling system components from
engine.
10. Drain engine oil into a suitable container.
Remove oil filter.

ENGINE Cylinder Head
CYLINDER HEAD
Cylinder Head Components
Figure 5-6
(1)
(21)
(4) (20)
(5) (22)
(2)
(15)
(2 )
(6) (11) (19)
(16)
(12) (14) (18)
(3) (7) (23)
(8)
(17)
(9)
(13) (25)
(10)
(24) (26)
(35)
(27)
(37)
(28)
(36)
(35)
(34) (33)
(32)
(31)
(29) (30)
0002258

Cylinder Head ENGINE
12/05
1 – Valve Bridge 19 – Unit Injector Rocker Arm

2 – Pin 20 – Jam Nut
3 – Bolt 21 – Adjusting Screw
4 – Valve Keeper 22 – Intake Valve Rocker Arm
5 – Valve Spring Collar 23 – Flange Bolt
6 – Exhaust Valve Spring 24 – Flange Bolt
7 – Exhaust Valve Spring 25 – Rocker Cover, Upper Section
8 – Valve Stem Seal 26 – Rocker Cover Gasket
9 – Valve Guide 27 – Rocker Cover, Lower Section
10 – Socket 28 – Rocker Cover Gasket
11 – Valve Keeper 29 – Exhaust Valve
12 – Valve Spring Collar 30 – Intake Valve
13 – Intake Valve Spring 31 – Valve Seat Insert
14 – Rivet Plug 32 – Gasket
15 – Tight-Fit Screw 33 – Rivet Plug
16 – Rocker Arm Shaft 34 – Alignment Pin
17 – Bearing Bracket 35 – Core Plug
18 – Exhaust Valve Rocker Arm 36 – Cylinder Head
37 – Unit Injector
Figure 5-6
General Guidelines Remove and Install Rocker Covers

NOTICE: Identify all parts and their location using Upper Rocker Cover
an appropriate method. It is important that all parts Figure 5-7
are returned to the same position during the

reassembly process.
Note: Record all measurements taken during
disassembly and inspection.
0002270
Figure 5-7
1. Clean the rocker cover and the surrounding
area.
2. Remove the upper rocker cover.
3. Clean all old gasket material and sealant from
the upper and lower rocker covers.
4. Install the upper rocker cover using a new
gasket.
5. Tighten bolts to 26 N·m (230 in.-lb).

Lower Rocker Cover

Figure 5-9
(1)
1. Remove upper rocker cover. See Upper Rocker
Cover on page 5-23.
Note: If the spring comes loose from the unit
injector, the unit injector must be
replaced.
Figure 5-8
0002272
Figure 5-9
3. Remove the rocker arm shaft assembly (Figure
5-9, (1)).
Figure 5-10
0002271
Figure 5-8
2. Remove bolts (Figure 5-8, (1)) retaining the
rocker arm shaft. Alternately loosen each bolt
until valve tension is relieved. CAUTION! Never
lean over the engine when removing the
rocker arm shaft. The unit injector spring is
under considerable tension and can
unexpectedly come loose and cause
personal injury.
0002275
Figure 5-10
4. Disconnect the electrical wires from the unit
injector. The screws cannot be removed
(Figure 5-10).

12/05
(2)
(1)
0002271
0002273A
Figure 5-12
Figure 5-11
11. Install the rocker arm shaft and rockers. Tighten
5. Remove the rocker arm shaft bracket (Figure the bolts (Figure 5-12, (1)) to 105 N·m
5-11, (1)). (77 ft-lb).
6. Remove the lower rocker cover (Figure 12. Check and adjust valve and injector clearance
5-11, (2)). when all cylinder heads have been installed.
7. Clean all old gasket material and sealant from See Adjust Valve and Unit Injector Clearances
the upper and lower rocker covers and the on page 5-18.
cylinder head. 13. Install the upper rocker cover and tighten the
8. Install the lower rocker cover using a new bolts to 26 N·m (230 in.-lb). See Upper Rocker
gasket. Cover on page 5-23.
9. Tighten bolts to 26 N·m (230 in.-lb).
10. Install the rocker arm shaft bracket. Tighten the
bolts to 105 N·m (77 ft-lb).

Remove the Cylinder Head 3. 8SY Engines:

1. Drain the coolant from the engine. (a) Remove the connection pipe between upper
intake manifold housings.
Figure 5-136SY Engines (b) Remove coolant recovery tank and catwalk.
(1) 4. Remove connection pipe(s) between charge air
cooler and turbocharger.
5. Remove the upper intake manifold. Remove the
intake air cooling element.
6. Remove bolts retaining intake manifold and fuel
manifold to cylinder head(s) to be removed.
Note: If all cylinder heads on the left-hand side
(cylinder numbers 5-8) are to be
removed, remove intake manifold and
fuel manifold.
(2)
3:5829A
If all cylinder heads on the right-hand

side (cylinder numbers 1-4) are to be
removed, remove charge air sensor,
Figure 5-13 intake manifold and fuel manifold.
Figure 5-148SY Engines 7. Remove cooling system ventilation pipe(s).
8. Clean rocker cover and the surrounding area.
(1)
9. Remove upper rocker cover, rocker arm shaft
assembly, pushrods and lower rocker cover.
(1) See Remove and Install Rocker Covers on
page 5-23.
10. Remove unit injector. See Remove the Unit
(3) Injector on page 6-8.
11. Remove intake manifold, fuel manifold and
exhaust manifold.
(2)
12. Remove cylinder head bolts and remove
cylinder head. Mark cylinder heads if removing
more than one at a time.
0002705B
13. Remove the cylinder head gasket.
Figure 5-14
2. Open bleeder valve(s) (Figure 5-13 and Figure
5-14 (1)) and drain fuel system by loosening
banjo bolt (Figure 5-13 and Figure 5-14 (2)) on
opposite end of fuel manifold. On 8SY engines,
also loosen union (Figure 5-14 (3)).

12/05
Disassemble the Cylinder Head Visually inspect parts. Replace any parts that are
Figure 5-15
obviously discolored, heavily pitted or otherwise
damaged. Discard any part that does not meet its
specified limit. NOTICE: Any part which is found
defective as a result of inspection or any part
whose measured value does not satisfy the
(1) standard or limit must be replaced.
NOTICE: Mark all valve train components so they
can be installed in their original locations.
Note: Record all measurements taken during
inspection.
Inspection of Intake and Exhaust Valves

Figure 5-15
Visually inspect intake and exhaust valves. Replace
1. Use OEM Part No. 99 322 (Figure 5-15, (1)) in any valves that are obviously discolored, heavily
a press, or an appropriate valve spring pitted or otherwise damaged.
compressor, to compress the valve springs.
Valve Recession
Remove valve keepers, valve spring retainers,
springs and valves. Note: Valve guides must be installed and in
good condition to perform this check.
2. Mark and place the valves in a rack so that they
can be installed in the same position in the
Figure 5-16
cylinder head.
3. Identify the cylinder heads if removing more
than one at a time.
Clean the Cylinder Head Components

Thoroughly clean all components using a
non-metallic brush and an appropriate solvent.
Each part must be free of carbon, metal filings and
other debris. WARNING! Always read and follow
safety-related precautions found on containers 0000193
of hazardous substances like parts cleaners, Figure 5-16

primers, sealants and sealant removers.
Inspect the Cylinder Head

Components
Clean all gasket material, sealant and carbon from
components. Use a suitable solvent and a soft
bristle brush to clean parts.

(1)
0001755
Figure 5-17
0001691B
Insert valves into their original locations and press
down until they are fully seated. Use a depth Figure 5-18
micrometer (Figure 5-16) to measure the distance
Coat the valve seat with a thin coat of bluing
between the cylinder head gasket surface and the
compound. Install valve and rotate to distribute
combustion surface of each exhaust and intake
bluing onto the valve face. The contact pattern
valve (Figure 5-17).
should be approximately centered on the valve face
Specifications (Figure 5-18, (1)) and even in width.
Inspection Item Standard Also visually inspect the valve seat for even
Valve Recession Intake 0.75 - 1.8 mm contact.
(0.030 - 0.071 in.)
Light cutting can be performed by the use of a
Exhaust 0.66 - 1.8 mm hand-operated cutter.
(0.026 - 0.071 in.)
Figure 5-19
Valve Face and Valve Seat

Always check the clearance between the valve and
valve guide before grinding or lapping the valve
seats. If the clearance exceeds the limit, replace
the valve and / or valve guide to bring the clearance
within the limit.
Roughness or burrs will cause poor seating of a
valve. Visually inspect the seating surfaces of each
valve and valve seat to determine if lapping or
grinding is needed.
Visually inspect all valves faces and valve seats for
pitting, distortion, cracking or evidence of
overheating. Usually the valves and valve seats can Figure 5-19
be lapped or ground to return them to serviceable
Note: Intake valve shown; exhaust valve is
condition. Severely worn or damaged components
similar.
will require replacement.

12/05
Valve seat diameter (Figure 5-19, (C)) can be

Figure 5-21
adjusted by bottom-grinding using a 60° stone to

make the seat diameter larger. Once the seat
location has been corrected, grind and lap the seat (1)
angle to specification. See Machine the Valve Seat
Inserts on page 5-30 for specifications.
Grinding is needed if the valve and the valve seat
do not contact correctly. Grind the valve face
and / or valve seat only enough to return them to
serviceable condition. Check valve recession after
grinding. Figure 5-21
If the valve or seat require grinding, lap the valve 4. Carefully install new valve stem seal using an
after grinding. Lap the valve face to the valve seat installer (OEM Part No. 99 323) (Figure
using a mixture of valve lapping compound and 5-21, (1)) and a hammer. WARNING! Avoid
engine oil. personal injury. ALWAYS wear safety
glasses when servicing the engine.
Be sure to thoroughly wash all parts to remove all
grinding powder or compound. Replace the Valve Seat
Replace the Valve Stem Seals Note: Oversize valve seat inserts are available
if the valve seat bore has been
1. Remove the valve. damaged. See the parts catalog for
Figure 5-20
available replacement parts.
Removal
1. Use a discarded valve that has been ground so
that the diameter of the disc is slightly smaller
than the inside diameter of the seat.
Figure 5-22
Figure 5-20
2. Remove valve stem seal with a pair of pliers
(Figure 5-20).
3. Install the valve.
Figure 5-22
2. Install a valve and weld it to the valve seat
(Figure 5-22). Cool with water.

Machine the Valves

Figure 5-23
Reface the valves using a valve face grinder.

Remove only enough material to return the valve to
serviceable condition.
Figure 5-25
Figure 5-23
Figure 5-25
3. Turn cylinder head over and drive valve and
seat out of cylinder head (Figure 5-23). Check valve margin (Figure 5-25, (A)) after
grinding is complete.
4. Cool the drift and valve seat to approximately
-112°F (-80°C) in dry ice or using liquid air. Machine the Valve Seat Inserts
WARNING! Use thermal gloves when
handling super-cooled components. Failure Specifications
to comply could result in moderate to
severe frost injuries. Pressing must be carried Intake Valve
out rapidly. Figure 5-26
Figure 5-24
(2)
(1)
0002284 Figure 5-26

Figure 5-24
5. Press in new valve seat inserts using drift (OEM
Part No. 99 384) (Figure 5-24, (1)) and driver
(OEM Part No. 99 385) (Figure 5-24, (2)).

12/05
Exhaust Valve
Figure 5-27
Figure 5-27
Item Intake Valve Exhaust Valve
Seat Contact Width (A) 1.9 - 2.6 mm (0.075 - 0.102 in.) 1.8 - 2.6 mm (0.071 - 0.102 in.)
Valve Recession (B) 0.75 - 1.8 mm (0.030 - 0.071 in.) 0.66 - 1.8 mm (0.026 - 0.102 in.)
Cutting Tool Setting - Diameter (C) 39.3 - 40.3 mm (1.547 - 1.587 in.) 37.3 - 38.3 mm (1.472 - 1.512 in.)
Seat Angle 20.0 - 20.5° 45.0 - 45.5°
Undercut Angle 60° 60°
Overcut Angle 60° -
Procedure
The following description applies to using a valve
seat cutter (OEM Part No. 587 277).
1. Check that cylinder head surface and the
magnetic base are smooth and clean. Clean
the valve guides using a wire brush and solvent.

Figure 5-31
Figure 5-28
Figure 5-31
Figure 5-28
5. Set the dial on the cutter adjuster using a valve
2. Select the largest spindle that slides easily into
(Figure 5-31).
the valve guide. Insert the spindle and turn the
feed screw to its uppermost position (Figure 6. Adjust the cutter diameter to the dimension
5-28). Seat Diameter (C) as listed the chart in
Figure 5-29 Machine the Valve Seat Inserts on page 5-30.
7. Disconnect the magnetic base. Insert the guide
spindle into the valve bushing. Adjust the pivot
plate so that the distance between the cutter
and the valve seat is approximately 1 mm
(0.039 in.). Center the tool precisely.
Figure 5-32
Figure 5-29
3. Select and install the cutter (Figure 5-29).
Figure 5-30
Figure 5-32
8. Connect the magnetic base (Figure 5-32).
9. Apply the quick-action lock. Make sure the
crank can be turned easily. If not, redo the
centering.
Figure 5-30
4. Release the quick-action lock and move the
pivot plate to the upper position with the
adjusting screw (Figure 5-30).

12/05
(1)
Figure 5-33
10. Machine the valve seat by cranking clockwise
Figure 5-35
while turning the feed screw. Never crank
counterclockwise, as this could damage the 2. Press in new valve guides using installation drift
cutter. Lubricate with cutting oil during the (OEM Part No. 99 382) (Figure 5-35, (1)).
procedure (Figure 5-33). Press guide down until tool contacts valve
11. When the machining of the valve seat is spring seat.
completed, reduce the cutting pressure by
turning the crank 2-3 turns without feeding. Replace the Unit Injector Sleeves
Continue to turn the crank while turning the • The cylinder head must be removed when
feed screw counterclockwise. The valve seat replacing the injector sleeve.
cutter is now ready for the next valve seat.
• The valves do not need to be removed. For clarity,
Replace the Valve Guides the illustrations show the cylinder head with
Figure 5-34 valves removed.
Figure 5-36
(1)
(1)
Figure 5-34
Figure 5-36
1. Press out valve guide using a removal drift
1. Use pilot tap and guide (Figure 5-36, (1)) to
(OEM Part No. 99 383) (Figure 5-34, (1)).
thread the bottom part of the sleeve.

3. Place the valve springs and valve spring

Figure 5-37
retainers on the cylinder head.

Figure 5-39
(1)
Figure 5-37
2. Use a 9 mm diameter metal rod, 100 mm long,
to drive out the pilot tap and sleeve from the
combustion side (Figure 5-37).
3. Degrease and check the contact surfaces of the Figure 5-39
sleeve and cylinder head. Remove any burrs 4. Compress the springs using a press and tool
and irregularities that may score the new (Figure 5-39, (1)), or a suitable valve spring
sleeve. compressor (OEM Part No. 99 322). Install the
4. Remove all grease from the new injector sleeve valve keepers, making sure they are seated
and apply a thin film of sealing agent (OEM Part inside the grooves in the valve stems.
No. 561 200) on the sleeve and cylinder head 5. Allow the valve spring to expand against the
contact surfaces. keepers. Repeat with remaining valves.
Figure 5-38
Install the Cylinder Head

1. Check liner height. See Measure the Cylinder
(1)
Liner Height on page 5-44.
2. Ensure the gasket surfaces of the cylinder head
(2) and cylinder block are clean and dry.
3. Install a new cylinder head gasket.
4. Install the cylinder head and ensure that the
guide pins fit correctly. NOTICE: The cylinder
head bolts can be reused up to three times.
Therefore, make sure the bolts have no more
than two punch marks on top of the bolt head. If
any bolt has three marks, it must be replaced
Figure 5-38 with a new one.
5. Press in the sleeve using drift (Figure 5-38, (1)) 5. Lightly lubricate the threads on the cylinder
and guide (Figure 5-38, (2)). head bolts and bolt holes.
Reassemble the Cylinder Head

1. Liberally lubricate all moving parts with clean
engine oil during reassembly.
2. Install new valve stem seals.

12/05
13. Connect turbocharger oil and water lines. Install

Figure 5-40
heat shields.
14. Install cooling system ventilation pipe(s) from
the cylinder head(s).
15. Install fuel manifold(s). Tighten bolts to 26 N·m
(230 in.-lb).
16. Connect fuel lines to fuel manifold(s). Tighten
union nuts to 20 N·m (133 in.-lb). Tighten return
line banjo bolts to 11 N·m (97 in.-lb). Install fuel
delivery pipe clamps.
17. Install lower intake manifold(s) using a new
gasket. Tighten bolts to 26 N·m (230 in.-lb).
0002293
18. Install charge air cooler(s) using a new gasket.
Figure 5-40 Tighten bolts to 20 N·m (177 in.-lb).
6. Tighten the bolts in the order shown in Figure 19. Install upper intake manifold(s). Tighten bolts
5-40 and in four stages as follows: to:
(a) Tighten all bolts to 60 N·m (44 ft-lb). • 6SY: 26 N·m (230 in.-lb)
(b) Tighten all bolts to 150 N·m (110 ft-lb). • 8SY: 50 N·m (37 ft-lb)
(c) Tighten all bolts to 250 N·m (184 ft-lb). 20. 8SY: Install connection pipe between intake
(d) Tighten all bolts an additional 90°. manifolds.
7. Make a mark with a center punch on the head 21. Connect coolant hoses to charge air coolers.
of the bolt. 22. Install and connect charge air sensor.
8. Install the unit injector. See Install the Unit 23. Install and secure all remaining air inlet pipes
Injector on page 6-11. and hoses. Tighten V-clamps to:
9. Install lower rocker cover, valve bridges, rocker • M6 Screw: 8 N·m (71 in.-lb)
shaft assembly, pushrods, and upper rocker • M8 Screw: 20 N·m (177 in.-lb)
covers. See Remove and Install Rocker Covers
on page 5-23. 24. 8SY: Install closed crankcase ventilation filter.
10. Check and adjust valve and injector clearance 25. Install and secure exhaust system connections.
after all cylinder heads have been installed. See 26. 8SY: Install coolant recovery tank and catwalk.
Adjust Valve and Unit Injector Clearances on 27. Fill engine with coolant.
page 5-18.
28. Connect negative (-) battery cable.
11. Install exhaust manifold. Tighten nuts and bolts
29. Bleed fuel system. See Bleed the Fuel System
to:
on page 6-17.
• 6SY: 59 N·m (44 ft-lb)
30. Start the engine and check for leaks.
• 8SY: 63 N·m (46 ft-lb)
12. Install turbocharger(s) (if equipped) and tighten
to:
• 6SY: 50 N·m (37 ft-lb)
• 8SY: 63 N·m (46 ft-lb)

ENGINE Pistons and Cylinder Liners
PISTONS AND CYLINDER LINERS

Figure 5-41
(1)
(2)
(3)
(4)
(5)
(6)
(8)
(7) (9)
(7)
(10)
(11)
(12)
(13)
(14)
(15)
0002300
1 – O-Ring 9 – Wrist Pin

2 – Cylinder Liner 10 – Wrist Pin Bushing
3 – O-Ring 11 – Connecting Rod
4 – Compression Ring 12 – Crankshaft
5 – Compression Ring 13 – Connecting Rod Bearing Insert
6 – Oil Scraper Ring 14 – Connecting Rod Cap
7 – Circlip (2 used) 15 – Rod Cap Bolt
8 – Piston
Figure 5-41
Note: 6SY components shown. 8SY is similar.

Pistons and Cylinder Liners ENGINE
12/05
Remove and Disassemble Piston and Figure 5-42
Connecting Rod
1. Remove the cylinder heads. See Remove the
Cylinder Head on page 5-26.
2. Remove oil sump. (1)
3. Remove the piston cooling nozzles from the
cylinder block. NOTICE: Use care not to
damage the piston cooling nozzles. The oil
spray must hit the piston precisely. If it does not,
the piston will become too warm, resulting in Figure 5-42
engine breakdown. Do not straighten damaged
nozzles. They must be replaced. 10. Place the connecting rod in a vise with soft
jaws. Remove the wrist pin retaining rings
4. Remove the ridge at the top of the cylinder if (Figure 5-42, (1)).
necessary. NOTICE: Engines with high Figure 5-43
operating hours may have a ridge near the top

of the cylinders that will catch the piston rings
and make it impossible to remove the pistons.
Use a suitable ridge reamer to remove ridges
and carbon prior to removing pistons.
Note: Pistons can fall from the cylinder block if (1)
the engine is inverted. Use care when
removing the connecting rod caps.
5. Remove the connecting rod cap and bearing
inserts.
6. Mark each piston and connecting rod before
removing them. They must be installed in the Figure 5-43
same location and orientation as they were 11. Push out the wrist pin using a drift (Figure
removed. NOTICE: Keep the piston pin parts, 5-43, (1)).
piston assemblies, and connecting rod
assemblies together to be returned to the same
position during the reassembly process. Label
the parts using an appropriate method.
7. Check the bearing oil clearance as each piston
and rod assembly is removed to help determine
extent of wear. See Measure the Oil Clearance
on page 5-85.
8. Push the piston and connecting rod out of the
cylinder. Use a wooden dowel against the
connecting rod, if necessary. NOTICE: Do not
allow the connecting rod to bump the crankshaft
journal during piston removal. Damage to the
bearing journal may result.
9. Wrap tape with the adhesive side out around
the crankshaft journal to protect it.

12. Separate piston crown from skirt. 1. Measure the wrist pin bushing bore (Figure
Figure 5-44
5-45, (2)) using a bore gauge (Figure
5-45, (1)). Replace the bushing if not within
(1)
specifications.
Specifications
Inspection Item Measurement
Wrist Pin Bushing ID 54.030 - 54.043 mm
(2.1272 - 1.1277 in.)
2. Place the connecting rod bearing inserts into

the connecting rod and connecting rod cap.
0002303 Install the rod cap and tighten the bolts to the
Figure 5-44 specified torque.
Torque Specifications
13. Use a piston ring expander (Figure 5-44, (1)) to
remove the piston rings, taking care not to Connecting Rod Bolt
Engine
scratch the surface of the piston. Torque
Note: When cleaning graphite-coated pistons 6SY 20 N·m (177 in.-lb)

plus 90°
in a machine, the graphite coating may
disappear. Used pistons are not affected 8SY 50 N·m (37 ft-lb)
plus 90°
by this condition. However, new pistons
should be cleaned carefully using an
appropriate parts cleaning solvent only, 3. Assemble the connecting rod to the alignment
and not cleaned by machine. tool. Install the wrist pin.
Note: The distance between the gauge studs is
Inspect the Connecting Rods 75 mm (2.953 in.).
NOTICE: Always inspect the connecting rod in
cylinders which have seized, been filled with water
or where a valve has broken. Bent connecting rods
must not be straightened.
Figure 5-45
(1)
(2)
0001724A
Figure 5-45

12/05
Figure 5-48
Figure 5-46
Figure 5-46
4. Place the gauge as shown in Figure 5-46. Use
a feeler gauge to measure clearance between
one gauge pin and the gauge surface to check Figure 5-48
connecting rod twist.
Figure 5-47 6. Check if the connecting rod is bent into an “S”
shape. Measure the distance from the outside
of the rod and the surface of the tool. Turn the
connecting rod 180° and measure again
(Figure 5-48).
Connecting Rod Specifications
Twist (Limit) 0.10 mm 0.05 mm
Bend (Limit) (0.004 in.) (0.002 in.)
Bend - “S” 0.60 mm 4.5 mm

Shape (Limit) (0.024 in.) (0.177 in.)
Figure 5-47
5. Place the gauge as shown in Figure 5-47. Use
a feeler gauge to measure clearance between
one gauge pin and the gauge surface to check
connecting rod bend.

Replace the Wrist Pin Bushing

Figure 5-50
Figure 5-49
(3)
Figure 5-50
(1) 2. Turn over the drift and mount a new bushing
(2) onto it. Press in the bushing (Figure 5-50).
Figure 5-51
d
0002304
1 – Press Plate with Guide Pin

2 – Press Drift
3 – Supports 0.007
0.008
Figure 5-49 0.008 A
There are different supports, depending on the

engine type (Figure 5-49).
The support marked with a “D” should be used for
the 6SY engine. The support marked with an “E”
should be used for the 8SY engine.
NOTICE: Check the connecting rod for bend before
replacing the wrist pin bushing. See Inspect the
Connecting Rods on page 5-38.
A
1. Install the correct support on the press plate 0002307
and place the connecting rod so that the wide

Figure 5-51
end of the connecting rod is resting against the
support. Place the press drift with the smaller 3. After pressing in new bushing, it must be
diameter against the bushing and press it out finish-turned. This requires special equipment.
(Figure 5-50). Refer to illustration for the dimensions required
(Figure 5-51).
Specifications
Item Specification
Diameter (d) 54.030 - 54.043 mm
(2.1272 - 2.1277 in.)
Surface Quality 0.6 Ra (roughness
average)

12/05
Inspect the Pistons and Piston Rings 5. Insert each piston ring (Figure 5-53, (1)), one
at a time, into the cylinder. Use a piston with the
1. Clean piston ring grooves using a piston ring piston rings removed to slide the ring into the
groove cleaning tool. Follow manufacturer’s cylinder bore until it is approximately 1.18 in.
instructions for correct operation. (30 mm) (Figure 5-53, (2)) from the bottom of
2. Wash pistons in an appropriate solvent using a the bore. Measure the end gap (Figure
soft brush. 5-53, (3)) of each piston ring.
3. Visually inspect each piston for cracks. Pay Specifications
particular attention to the ring lands between
the piston ring grooves. Inspection Item Standard Limit
Note: The top piston ring is tapered and cannot Top Side - -
Ring Clearance
be checked for side clearance.
End Gap 0.35 - 0.60 mm
Figure 5-52
(0.014 - 0.024 in.)

Second Side - 0.25 mm
Ring Clearance (0.010 in.)
End Gap 0.45 - 0.65 mm -
(0.018 - 0.026 in.)
Oil Ring Side - 0.25 mm
Clearance (0.010 in.)
End Gap 0.40 - 0.65 mm -
(0.016 - 0.026 in.)
6. Repeat the above steps for each of the

0001892 cylinders and the piston rings for that specific
cylinder.
Figure 5-52
Assemble the Piston and Connecting
4. Place a new piston ring in the oil groove as
shown (Figure 5-52). Use a feeler gauge to
Rod
measure the gap between the ring and the 1. Clean the piston and rings thoroughly without
piston. Replace the piston if not within scratching the sides of the ring grooves. The oil
specification. Repeat with the second ring. holes in the piston should be cleaned using a
Figure 5-53
suitable drill.
2. Oil all the bushings, wrist pin bore and wrist pin
before assembling.
3. Place one of the retaining rings in the piston
crown. Assemble the crown and skirt.
(1)
(2)
(3)
0001964
Figure 5-53

Figure 5-54
(1)
0002309
Figure 5-54
Figure 5-56
4. Orient the piston and connecting rod (Figure
5-54). The arrow (Figure 5-54, (1)) on top of 6. Install the piston rings using a piston ring tool.
the piston must be on the same side as the cap The oil scraper ring has an expander
side of the connecting rod big end. underneath it (Figure 5-56). Put the expander
Figure 5-55
end gap and oil ring end gap 180° apart.
Stagger all exposed ring gaps 120° from each
other.
Remove the Cylinder Liners

(1)
Figure 5-55
5. Insert the wrist pin using a tool (Figure
5-55, (1)), if necessary. Install the second
retaining ring.
Note: Piston rings marked with TOP must be
installed with TOP facing up.
Figure 5-56
Figure 5-57

12/05

Figure 5-59
(2)
(1)
0002312
Figure 5-59
2. Remove the cylinder liner using a puller (Figure
5-59, (1)) and hydraulic cylinder (Figure
Figure 5-58 5-59, (2)). Install spacers under the support
1. Mark each liner with the appropriate cylinder lugs to avoid damaging the gasket surface of
number (Figure 5-57) or (Figure 5-58). the block.
NOTICE: The mark must be made only on the 3. Remove the sealing ring in the cylinder block.
surface indicated in Figure 5-57. Other
surfaces are used for sealing.

Measure the Cylinder Liner Height Install the Cylinder Liners

1. Thoroughly clean the cylinder block liner flange, 1. Check cylinder liner height. See Measure the
the sealing face around the cylinder, the Cylinder Liner Height on page 5-44. Choose the
cylinder liner flange and the upper face of the appropriate shims as necessary. See Cylinder
cylinder liner. Liner on page 5-8 for available sizes.
2. Install the cylinder liner without O-rings and 2. Make sure the liner bore of the cylinder block is
twist down by hand into position. clean. Clean the O-ring surfaces.
3. Check that the coolant passages going to the
Figure 5-60
(2) (1)
(3) cylinder head and cylinder liner are not
D clogged.
C
C 4. Carefully check the cylinder liners, both new
B A and used, for cracks which might have occurred
during transport or careless handling.
• Tap the liner carefully with a metal object. If
intact, It should give a clear metallic ring. If not,
0002313
replace liner.
3. Place a dial indicator on the liner at position “A”

(Figure 5-60, (1)) and zero the dial indicator.
Slide the tip of the dial indicator over to the
cylinder block (position “B”) (Figure 5-60, (2))
and read the dial indicator. Measurement (D)
(Figure 5-60, (3)) is the reading on the dial
indicator. Record each measurement taken.
4. Measure each liner at two diametrically
opposite points 180° apart. Figure 5-61
The cylinder liner must be above the face of the 5. Lubricate the sealing surfaces with engine oil
cylinder block per the specification. Add or (Figure 5-61).
remove shims from under liner to achieve correct 6. Install O-rings on the liner and lubricate with
protrusion. engine oil.
Specifications
Figure 5-62
Inspection Item Specification

Dimension D 0.15 - 0.30 mm
(0.006 - 0.012 in.)
Protrusion Variation on 0.02 mm (0.0008 in.)
One Liner (Maximum)
Figure 5-62
7. Install the liner with the stamped cylinder
number facing forward and carefully tap it down
with a non-metallic mallet (Figure 5-62).

12/05
Install the Piston and Connecting

Figure 5-64
Rod (1)
1. Lubricate the piston, piston rings, cylinder liner,
and piston ring compressor with clean engine
oil.
Figure 5-63
Figure 5-64
7. Using a piston ring compressor (Figure
5-64, (1)), carefully install the connecting rod
and piston so that the arrow mark on the piston
points toward the coolant pump end of the
engine.
Figure 5-65
0000226
Figure 5-63
2. Turn the piston rings so that the ring gaps are
distributed evenly around the piston (Figure
5-63). NOTICE: Ensure the bearing inserts, and
connecting rod and cap mounting surfaces are 0002317
absolutely clean.
Figure 5-65
3. Install the connecting rod bearing inserts in the
connecting rod and cap. 8. Install the connecting rod cap. Ensure the
connecting rod and cap have the same marking
4. Apply a light coat of clean engine oil to the
number and that the marks are on the same
bearing insert.
side.
5. Rotate the crankshaft so the journal for the
9. Lubricate the bolts and install (Figure 5-65).
piston being installed is near BDC.
Tighten to specification.
6. Remove the protection on the connecting rod
journal and apply a light coat of clean engine Specifications
oil. Item 6SY 8SY
Connecting Rod 20 N·m 50 N·m (37 ft-lb)
Cap Torque (177 in.-lb) plus plus 90°
90°

10. Install the piston cooling nozzles and tighten

the banjo bolts to 23 N·m (17 ft-lb). NOTICE:
Use care not to damage the piston cooling
nozzles. The oil spray must hit the piston
precisely. If it does not, the piston will become
too warm, resulting in engine breakdown. Do
not straighten damaged nozzles. They must be
replaced. Check that the piston cooling nozzles
are in perfect condition and fully open. If
necessary, clean with compressed air.
CAUTION! ALWAYS wear eye protection
when servicing the engine and when using
compressed air or high-pressure water.
Dust, flying debris, compressed air,
pressurized water or steam may injure your
eyes.
11. Install the oil sump and tighten the bolts to
30 N·m (22 ft-lb).
12. Install the cylinder head. See Install the

12/05

ENGINE Flywheel and Flywheel Housing
FLYWHEEL AND FLYWHEEL HOUSING

Flywheel Housing Components - 6SY Engines
Figure 5-66
(22)
(17) (20)
(24)
(21)
(7)
(19) (18)
(23)
(5) (16) (9) (29) (31)
(8)
(25) (10) (32)
(26) (4)
(3)
(25)
(2) (12)
(37)
(1) (35)
(36)
(29)
(15) (13) (30) (31)
(6) (14) (34) (32)
(11)
(33)
(31) (33)
(30) (35)
(32)
(33)
(29) (33)
(34)
(35)
0002318

Flywheel and Flywheel Housing ENGINE
12/05
1 – Flywheel Housing 20 – Clamp

2 – Seal 21 – Bolt
3 – Bolt 22 – Crankshaft
4 – Washer 23 – Timing Gear Plate
5 – Flange Bolt 24 – Stud
6 – Flange Bolt 25 – Pin
7 – Flange Bolt 26 – Flange Bolt
8 – Cover 27 – Cover
9 – Gasket 28 – O-Ring
10 – Flange Bolt 29 – Crankshaft Gear
11 – Timing Window Cover 30 – Pin
12 – Lifting Eye 31 – Ring Gear
13 – Hexagon Nut 32 – Flywheel
14 – Washer 33 – Circlip
15 – Stud 34 – Ball Bearing
16 – Engine Speed Sensor 35 – Bolt
17 – Wire Connector 36 – Washer
18 – Flange Bolt 37 – Guide Sleeve
19 – Clamp
Figure 5-66

Flywheel Housing Components - 8SY Engines

Figure 5-67
(2) (3)
(1)
(4)
(9)
(10)
(5)
(7)
(8)
(6)
0003044
1 – Flywheel Housing 6 – Timing Window Cover

2 – O-Ring 7 – Engine Speed Sensor
3 – Housing 8 – Rear Crankshaft Seal
4 – Flange 9 – Gasket
5 – O-Ring 10 – Engine Speed Sensor
Figure 5-67

12/05
Remove the Flywheel

Figure 5-70
(1)
Figure 5-68
(2)
(1)
Figure 5-70
5. Use jack bolts (Figure 5-70, (1)) to remove the
flywheel from the crankshaft.
Figure 5-71
Figure 5-68
Note: 6SY engine shown. 8SY engine is
similar.
1. Remove the engine speed sensor(s) (Figure
5-68, (1)) from the flywheel housing.
2. Install a flywheel holder (Figure 5-68, (2)).
3. Remove the bolts retaining the flywheel.
CAUTION! The flywheel is heavy and may
fall unexpectedly. Always use guide pins
and wear gloves when removing or
installing the flywheel.
Figure 5-69
Figure 5-71
Note: The flywheel can be lifted using two
M10 x 100 bolts threaded into the
flywheel (Figure 5-71).
(1)
0002325
Figure 5-69
4. Install two guide pins (Figure 5-69, (1)).

Flywheel Inspection and Repair 5. Place heated ring gear on flywheel so that the
marking with the part number is facing the
Support Bearing Replacement engine when the flywheel is installed. Make
1. Remove retaining rings from both sides of sure ring gear is securely against flywheel.
support bearing. Ensure ring gear is fully seated by tapping with
Figure 5-72
non-metallic hammer.
(1) 6. The ring gear must not be cooled rapidly but be
left to cool in the open air.
Replace the Rear Crankshaft Seal

1. Remove flywheel. See Remove the Flywheel on
page 5-51.
2. Remove crankshaft seal using a screwdriver.
Take care not to scratch the sealing surfaces on
the crankshaft and the flywheel housing.
Note: The crankshaft seal must be installed dry
Figure 5-72 and must not be lubricated. The sleeve in
the seal should be left in place until the
2. Drive out support bearing from flywheel using a seal is installed. The crankshaft should
driver (Figure 5-72, (1)). be degreased before the new seal is
3. Install inner retaining ring. Drive in new support installed.
bearing using drift. Drive only against outer Figure 5-73
race of bearing. (1)

4. Install the outer retaining ring.
Remove the Ring Gear

Replace flywheel ring gear if gear teeth are
chipped, broken, or have become so worn that
starter motor pinion will not engage properly.
1. Grind a groove as deep as possible in ring gear
and crack it open with a chisel. CAUTION!
ALWAYS wear safety glasses while
servicing the engine.
2. Remove ring gear from flywheel.
3. Clean the contact surfaces on flywheel with a
wire brush.
4. Heat new ring gear evenly around its Figure 5-73
circumference to 100 - 150°C (212 - 302°F).
3. Place crankshaft seal on tool and fasten tool to
CAUTION! Handle hot components with
the crankshaft (Figure 5-73, (1)).
heat-resistant gloves.
4. Turn tool clockwise until it stops. The seal will
be at the correct installed position.
5. Remove tool.

12/05
6. Install flywheel. See Install the Flywheel on

Figure 5-74
page 5-54. M10 x 60
Remove the Flywheel Housing M12

page 5-51.
2. Remove starter motor. See Remove and Install
Starter Motor on page 10-7.
3. Remove PTO cover or hydraulic pump (if
equipped). Place to one side.
4. Remove closed crankcase ventilation filter.
5. Remove turbocharger oil lines.
6. Remove seawater pump and connecting pipes.
7. 8SY: Remove oil sump.
8. Remove flywheel housing.
Install the Flywheel Housing

M12 0002323
1. Remove all old gasket material and sealing
compound from the sealing surfaces of the Figure 5-74
flywheel housing and mounting surfaces of the Figure 5-75
engine. Clean off any oil and grease using an

alcohol-based cleaning agent.
Note: The sealing surfaces must be absolutely
clean and free from grease. Do not touch
the surfaces after degreasing.
2. NOTICE: Assembly must be completed within
25 minutes of starting to apply the sealing
agent.
6SY: Install flywheel housing as follows:
(a) Apply sealing agent (OEM Part No. 816 064)
on timing gear plate side of flywheel
housing. The width of the bead should be
45 0002324
0.8 - 1.2 mm (0.031 - 0.047 in.). Apply
sealing agent around bolt holes. NOTICE: Figure 5-75
Ensure that sealing agent is applied inside
Note: The bolts are of various sizes and
the bolt holes, but without allowing sealing
lengths. Ensure that they are installed in
agent into the crankcase. Excess sealing
the correct places.
agent may block channels and nozzles,
particularly around oil passages. (b) Install bolts. Tighten M12 bolts to 90 N·m
(66 ft-lb) and M10 bolts to 50 N·m (37 ft-lb)
(Figure 5-75).

3. 8SY: Install flywheel housing as follows: 5. Install PTO cover or hydraulic pump (if
Figure 5-76
equipped).
6. Install seawater pump and connect lines.
7. Install turbocharger oil lines.
8. Install closed crankcase ventilation filter and
connect lines.
9. Install starter motor. See Remove and Install
page 5-54.
Install the Flywheel

1 1
Figure 5-77
2 2
(1)
0002325
Figure 5-77
Note: 6SY engine shown. 8SY engine is
similar.
1. Install two guide pins (Figure 5-77, (1)) in the
crankshaft flange. NOTICE: Never reuse
flywheel bolts. Always install new flywheel bolts.
B112295A
Figure 5-76
(a) Cut portions (2) from new gasket and place
in locations (1) on engine block. Hold in
place with a small amount of sealant.
(b) Install flywheel housing using remainder of
new gasket.
(c) Install bolts. Tighten M12 bolts and studs to
90 N·m (66 ft-lb) and M10 bolts to 50 N·m
(37 ft-lb) (Figure 5-76).
4. 8SY: Install oil sump using a new gasket.
Tighten bolts to 32 N·m (24 ft-lb).

12/05
5. Remove the flywheel holder and install the

Figure 5-78
engine speed sensor(s).
Figure 5-78
Note: The flywheel can be lifted using two
M10 x 100 bolts threaded into the
flywheel (Figure 5-78).
2. Install the flywheel on the crankshaft. Install
bolts. If equipped with a 14-in. flywheel, install
washers.
Figure 5-79
(2)
(1)
Figure 5-79
3. Install a flywheel holder (Figure 5-79, (2)) in
one of the sensor (Figure 5-79, (1)) holes.
4. Tighten the flywheel bolts alternately to
130 N·m (96 ft-lb) and then a further 90°.

ENGINE Timing Gear Train
TIMING GEAR TRAIN

6SY Components
Figure 5-80
(30)
(33)
(28) (34)
(27) (29)
(31) (32)
(26)
(25)
(5)
(3)
(1)
(8) (2)
(9)
(4)
(6)
(7)
(15)
(13) (14)
(12) (21)
(11) (18)
(24)
(10) (23)
(22)
(19) (20)
(17)
0002328
(16)

Timing Gear Train ENGINE
12/05
1 – Camshaft 18 – Crankshaft Gear

2 – Camshaft Bearing 19 – Oil Pump Gear
3 – Pin 20 – Compressor Gear
4 – Guide Flange 21 – Intermediate Gear
5 – Flange Bolt 22 – Snap Ring
6 – Thrust Washer 23 – Shaft
7 – Camshaft Gear 24 – Spacing Sleeve
8 – Flange Bolt 25 – Roller Tappet
9 – Hydraulic Pump Wheel 26 – Circlip
10 – Flange Bolt 27 – Flange Bolt
11 – Shaft 28 – Banjo Bolt
12 – Intermediate Gear 29 – Tappet Shaft
13 – Ball Bearing 30 – Pushrod
14 – Snap Ring 31 – Guide Sleeve
15 – Spacing Sleeve 32 – Snap Ring
16 – Bolt 33 – Pushrod
17 – Shaft 34 – Roller Tappet
Figure 5-80

8SY Components
Figure 5-81
(3)
(1)
(2)
(4)
(5)
(6)
(15) (16)
(8) (7)
(9)
(10)
(14)
(17)
(18)
(11)
(19)
(20)
(21)
(22)
(13)
(12) (28)
(27)
(23)
(26)
(25)
(24)
(25)
(29) 0003060

12/05
1 – Pushrod 16 – Seawater Pump Gear

2 – Tappet Shaft 17 – Intermediate Gear Shaft
3 – Circlip (4 used) 18 – Intermediate Timing Gear
4 – Camshaft Gear, Right 19 – Oil Pump Gear
5 – Thrust Washer 20 – Ball Bearing
6 – Guide Flange 21 – Snap Ring
7 – Alignment Pin 22 – Spacer
8 – Guide Sleeve (2 used) 23 – Gear, Optional Power Take-Off
9 – Roller Tappet 24 – Spacer
10 – Camshaft, Right 25 – Intermediate Gear (2 used)
11 – Front Camshaft Gear (left side only) 26 – Ball Bearing (4 used)
12 – Fuel Feed Pump Drive Gear 27 – Snap Ring (2 used)
13 – Hydraulic Pump Drive Gear (if equipped) 28 – Shaft (2 used)
14 – Camshaft, Left 29 – Crankshaft Gear
15 – Camshaft Gear, Left
Figure 5-81

Check the Camshaft Timing Left Camshaft

1. Adjust unit injector on No. 6 cylinder. See
6SY Engines Adjust the Unit Injectors on page 6-7. The
1. Set crankshaft to TDC of compression stroke engine position will be such that “TDC Up
on cylinder No. 1. (180°)” is visible in timing window of the
flywheel.
2. Set two dial indicators against the valve spring
retainers of an intake and exhaust valve on 2. Zero dial indicator against the spring collar on
No. 1 cylinder. the unit injector.
3. Adjust rocker arms so that both valves are open 3. Turn flywheel 180° in the direction of rotation so
0.1 mm (0.004 in.). that “TDC Down (360°)” is visible in timing
window of flywheel housing.
4. Zero both dial indicators.
4. Compare reading on dial indicator with
5. Turn crankshaft one revolution in direction of
specifications.
rotation until TDC position is again achieved.
6. Read both dial indicators and compare with Camshaft Timing Specifications
specifications: Inspection Item Specification
Specifications Dial Indicator Reading at 4.5 - 5.1 mm
Given Crankshaft Position (0.177 - 0.201 in.)
Valve Measurement
Intake 0.37-1.47 mm (0.015-0.058 in.) Remove the Front Gear Housing -
Exhaust 0.16-1.16 mm (0.006-0.046 in.) 8SY
7. Adjust valves to correct clearance. See Adjust 1. Drain engine coolant.
Valve and Unit Injector Clearances on 2. Remove belt guard and poly V-belt.
page 5-18.
8SY Engines
Right Camshaft
1. Adjust unit injector on No. 1 cylinder. See
Adjust the Unit Injectors on page 6-7. The
crankshaft position will be such that “TDC Up
(540°)” is visible in the timing window of the
flywheel housing.
2. Zero dial indicator against the spring collar on
the unit injector.
3. Turn flywheel 180° in the direction of rotation so
that “TDC Down (0°)” is visible in the timing
window of flywheel housing.
4. Compare reading on dial indicator with
specifications.

12/05
(4)
(3)
Figure 5-83
(1) 7. Remove 15 bolts and remove front gear
housing (Figure 5-83).
(2)
0003043
Figure 5-82
3. Disconnect fuel line connections from fuel feed
pump (Figure 5-82, (1)).
4. Remove coolant temperature sensor and oil
pressure sender (Figure 5-82, (2)).
5. Remove hydraulic pump (if equipped) (Figure
5-82, (3)) and swing to one side.
6. Remove oil filter housing (Figure 5-82, (4))
from gear housing.

Install the Front Gear Housing - 8SY Intermediate Gear

Figure 5-84
Remove
• The 6SY timing gear train has two intermediate
(4) gears. One drives the camshaft and one drives
the seawater pump. Both gears should be
removed in the same manner.
• The 8SY timing gear train has three intermediate
gears. One drives the camshafts, the other two
drive an optional PTO gear.
Figure 5-85
(3)
(1) (1)
(2)
0002259
Figure 5-85
0003043
1. Use a flywheel turning tool (Figure 5-85, (1)) to
Figure 5-84 turn the crankshaft so that No. 1 cylinder is
approximately at TDC on the compression
1. Install front gear housing (Figure 5-84) using
stroke (both valve rocker arms loose). “Down
new gasket.
TDC (0°)” will be visible in the lower timing
2. Install oil filter housing. window of the flywheel housing.
3. Connect fuel line connections to fuel feed pump 2. Remove flywheel. See Remove the Flywheel on
(Figure 5-84, (1)). page 5-51.
4. Install hydraulic pump (if equipped) (Figure 3. Remove flywheel housing. See Remove the
5-84, (3)). Flywheel Housing on page 5-53.
5. Install coolant temperature sensor and oil
pressure sender (Figure 5-84, (2)).
6. Install poly V-belt and belt guard.
7. Fill engine with coolant.

12/05

Figure 5-86
(1)
Figure 5-86
4. 8SY: Temporarily secure crankshaft gear using
flywheel bolts with 50 mm (2 in.) spacers
(Figure 5-86, (1)).
Figure 5-88
5. Ensure all timing marks are aligned (Figure
5-87) or (Figure 5-88).
Figure 5-89
min 20
M10 Ø 15-20
0002329
0002334

6. 6SY: Fabricate a thread block according to the
sketch (Figure 5-89). (Measurements are in
millimeters.)
7. Check intermediate gear end play using a dial
indicator. If not within specification, replace
bearings after removal. See Bearing
Replacement - 6SY on page 5-64 or Bearing
Replacement - 8SY on page 5-65.
Specifications
Inspection Item Limit
Timing Gear End Play 0.238 mm (0.009 in.)

(1)
(3)
(2) 0002674A
(1)
Figure 5-90
8. Remove bolt (Figure 5-90, (1)) retaining
intermediate gear.
Figure 5-91
(1)
Figure 5-92
(2)
10. 8SY: Remove gear, shaft and spacer using a
slide hammer. Pull alternately from the two
timing holes (Figure 5-92, (1)). NOTICE: Do
not allow the crankshaft to turn while the timing
gear train is disassembled.
Bearing Replacement - 6SY

Figure 5-91
Intermediate Gear for Seawater Pump
9. 6SY: The shaft on which the gear is located has Figure 5-93
a groove. Install puller (Figure 5-91, (1)), slide

hammer (Figure 5-91, (2)) and the shop-made
thread block. (4)
• 6SY: Remove the gear, shaft (Figure 5-90, (2)) (3)
and spacer (Figure 5-90, (3)).
• Repeat steps on remaining intermediate gear.
(2) 0002674
(1)
Figure 5-93
1. Remove snap ring (Figure 5-93, (3)).
2. Press bearing (Figure 5-93, (4)) out of gear
(Figure 5-93, (2)).
3. Press shaft (Figure 5-93, (1)) out of bearing.
NOTICE: Do not press on the outer race.
4. Press shaft into a new bearing.
5. Press ring on shaft journal.
6. Press bearing packet into intermediate gear.
7. Install snap ring.

12/05
Intermediate Gear for Camshaft

Figure 5-96
Figure 5-94
(4)
(3)
(1) (2) 0002673
Figure 5-94
1. Press shaft (Figure 5-94, (1)) out of bearing Figure 5-96
(Figure 5-94, (3)).
2. Remove spacing sleeve and snap ring (Figure
2. Press bearing inner race shell from shaft and 5-96).
remove retaining ring (Figure 5-94, (4)). Figure 5-97
3. Place removed bearing inner race in bearing

and press out bearing (Figure 5-93, (3)).
4. Press a new bearing onto shaft journal.
NOTICE: Do not press on the outer bearing
race.
5. Press bearing and shaft journal into
intermediate gear.
6. Install snap ring.
7. Support end of shaft on press table and press
spacing ring onto shaft journal.
Figure 5-97
Bearing Replacement - 8SY
Figure 5-95
3. Turn gear over. Press bearing and shaft from
gear (Figure 5-97).
4. Press bearing off of shaft.
Figure 5-95
1. Press shaft until it is flush with face of small
gear (Figure 5-95).

Intermediate Gear Installation

Figure 5-98

(1)
(3)
(2)
0002333
Figure 5-100
Figure 5-98
5. Press a new bearing onto shaft (Figure 5-98).
Figure 5-99
(1)
(3)
(2)
0003071
Figure 5-101
1. Check that cylinder No. 1 is at TDC (both valve
Figure 5-99
rocker arms loose). “Down TDC (0°)” will be
6. Press bearing and shaft into gear until it stops. visible in the lower timing window of the
Use care to press only on the outer bearing flywheel housing.
race using the tube section of tool (Figure 2. The timing marks on the camshaft gear (Figure
5-99). 5-100 (1)) and Figure 5-101 (1)) and
7. Install retaining ring. crankshaft gear (Figure 5-100 (2)) and Figure
5-101 (2)) must point toward the center of the
8. Support end of shaft on press table and press
intermediate gear mounting hole (Figure 5-100
spacer ring until it seats against bearing.
(3)) and Figure 5-101 (3)).

12/05
3. Lubricate bearing surfaces. Note: 6SY: The installation procedure for the
seawater pump intermediate gear is the
Figure 5-1026SY same except there are no timing marks
to align.
6. 6SY: Repeat steps for seawater pump
intermediate gear.
7. Install flywheel housing. See Install the
Flywheel Housing on page 5-53.
page 5-54.
9. Check valve timing to verify installation. See
Check the Camshaft Timing on page 5-60.
Camshaft Gear
Remove
Figure 5-104
0002334
Figure 5-102
Figure 5-1038SY
(1)
0002259
Figure 5-104
1. Use a flywheel turning tool (Figure 5-104, (1))
to turn the crankshaft so that No. 1 cylinder is
window of the flywheel housing.
Figure 5-103 page 5-51.
4. Install camshaft intermediate gear and shaft 3. Remove flywheel housing. See Remove the
assembly. Ensure timing marks (Figure 5-102 Flywheel Housing on page 5-53.
and Figure 5-103) are aligned. 4. Remove camshaft intermediate gear. See
5. Install bolt. Torque-turn tighten to 50 N·m Intermediate Gear on page 5-62. NOTICE: Do
(37 ft-lb) plus 60°. not allow the crankshaft to turn while the timing

8SY Engines: The camshaft gears differ between

Figure 5-105
the left and right sides. The left camshaft gear can
be identified by having raised bosses as shown in
Figure 5-106 and is used for engine speed
indication.
Figure 5-107
Figure 5-105
5. Remove camshaft gear and thrust washer
(Figure 5-105). Figure 5-107
Install 6. Install camshaft gear and tighten bolts to
Figure 5-106
63 N·m (46 ft-lb) (Figure 5-107).
7. Install intermediate gear. See Intermediate
Gear on page 5-62.
page 5-54.
Figure 5-106

12/05
Crankshaft Gear
Figure 5-109
Remove
Figure 5-108
(1)
0002339
Figure 5-109
5. Remove the crankshaft gear. Use a puller or pry
0002259
bar to remove the gear if necessary (Figure
Figure 5-108 5-109).
Install
to turn the crankshaft so that No. 1 cylinder is Figure 5-110

2. Remove the flywheel. See Remove the
Flywheel on page 5-51.
3. Remove the flywheel housing. See Remove the
4. Remove the intermediate gear(s). See
Intermediate Gear on page 5-62. NOTICE: Do
not allow the crankshaft to turn while the timing 0002340
Figure 5-110
1. Install the crankshaft gear and guide pin
(Figure 5-110).
2. Install the intermediate gears. See Intermediate
Gear on page 5-62.
3. Install the flywheel housing. See Install the
4. Install the flywheel. See Install the Flywheel on
page 5-54.

Remove the Camshaft Figure 5-1138SY Engines

1. Drain cooling system. Use a suitable container
of sufficient volume. (1)
Figure 5-111
(1)
(3)
(1)
(2)
0002705B
0002259 Figure 5-113

Figure 5-111 4. Open bleeder valve(s) (Figure 5-112, (1) or
(Figure 5-113, (1)) and drain fuel system by
loosening banjo bolt (Figure 5-112, (2) or
to turn the crankshaft so that No. 1 cylinder is
(Figure 5-113, (2)) on the opposite end of the
fuel manifold. On 8SY engines, also loosen
union (Figure 5-112, (3) or (Figure 5-113, (3)).
DANGER! When you remove any fuel
system component to perform maintenance
3. Clean the rocker cover and the surrounding put an approved container under the
area. NOTICE: Identify all parts and their opening to catch the fuel. NEVER use a
location using an appropriate method. It is shop rag to catch the fuel. Vapors from the
important that all parts are returned to the same rag are flammable and explosive. Wipe up
position during the reassembly process. any spills immediately. Wear eye protection.
Figure 5-1126SY Engines The fuel system is under pressure and fuel
could spray out when you remove any fuel
(1) system component.
5. 8SY Engines:
(a) Remove connection pipe between charge
air coolers.
(b) Remove coolant recovery tank and catwalk.
6. Remove connection pipe(s) between charge air
cooler and turbocharger.
7. Remove centrifugal oil cleaner and oil cooler.
8. Remove cooling system ventilation pipe(s).
(2) NOTICE: Mark all valve train components so
they can be installed in their original locations.
829A
Figure 5-112

12/05
9. Remove upper rocker covers, rocker arm shaft Figure 5-1156SY Engine Shown
assemblies, pushrods and lower rocker covers
from all cylinder heads. See Remove and Install
Rocker Covers on page 5-23.
page 5-51.
11. Remove flywheel housing. See Remove the
Flywheel Housing on page 5-53. NOTICE: Do
not allow the crankshaft to turn while the timing
12. Remove the intermediate gear(s). See 0002342
Intermediate Gear on page 5-62.
Figure 5-115
13. Check camshaft end play.
19. Remove roller tappets (Figure 5-115).
Specifications
20. Remove camshaft from cylinder block. Take
Inspection Item Measurement care not to damage the lobes or bearings.
Camshaft End Play 0.10 - 0.25 mm
(0.004 - 0.010 in.) Replace the Camshaft Bearings - 6SY
1. Remove the camshaft. See Remove the
14. Remove camshaft gear. See Camshaft Gear on Camshaft on page 5-70.
page 5-67.
2. 6SY: Remove camshaft cover at front end of
15. 8SY Engines: Remove front gear housing. See the engine.
Remove the Front Gear Housing - 8SY on
page 5-60. Remove front camshaft gear from 3. Wipe all residue from the bearing bores and the
left camshaft. edges of the old bearings. NOTICE: The new
bearings are used to remove the old bearings.
16. 6SY Engines: Remove timing gear plate. Any debris along the edge of the bearing can
17. Remove guide flanges. cause damage to the new bearing during
installation. Be sure the old bearing and bearing
Figure 5-1146SY Engine Shown bore are clean.
Figure 5-116
0002345
Figure 5-116
Note: All dimensions are metric.
0002341
Figure 5-114
18. Remove tappet covers (Figure 5-114).

(3)
(1)
(2) 0002344
0002343A
1 – Threaded Rod with Eight Flange Nuts

2 – Press Drift
3 – Flange 0002346

4. Assemble the installation tool as shown in 5. Place new bearings in the spaces between the
Figure 5-117. Position nuts as shown in Figure camshaft bearing seats (Figure 5-118).
5-116. NOTICE: The notch in the bearing joint must be
turned toward the front of the engine.
6. Insert the threaded stem through the camshaft
bore from the rear of the engine until the end
flange nut protrudes from the front of the
engine.

12/05
(1)
(2)
(3)
(3)
(1)
0002347
(2)
Figure 5-119
7. Attach flange (Figure 5-119, (1)) securely to
hydraulic cylinder (Figure 5-119, (2)) with two
M6 x 12 bolts. Be sure the cylinder is fully
retracted.
8. Attach flange and cylinder securely to rear of
engine with two M10 x 25 bolts.
0002348
9. Install flange nut (Figure 5-119, (3)).
Figure 5-120
10. Place a new bearing (Figure 5-120, (1)) on the
stem at the front of the engine.
11. Place press drift (Figure 5-120, (2)) on the
threaded rod and place the bearing on the drift.
The notch in the bearing joint must be against
the flange on the drift. Secure the bearing on
the drift by placing the spring-loaded ball in an
oil hole. The bearing is correctly located on the
drift when the ball and a marking hole are
centered on the bearing oil hole.
Note: Camshaft bearings No. 2, 4 and 6 have
two oil ports. The others only have the
lower port.
12. Ensure the edges of the old and new bearings
are clean. The V-groove (Figure 5-120, (3)) on
the drift must be up and vertical to correctly
align the oil holes in the bearing with the oil
passages in the cylinder block.

0002349
Figure 5-123
14. Press in the new bearing while pressing out the
old bearing. The bearing is correctly installed
when the dimension from the front of the
cylinder block to the drift is within the installed
distance specification. See Camshaft Bearing
Installed Specifications - 6SY Engines on
page 5-74.
Camshaft Bearing Installed Specifications -
6SY Engines
0002350 Camshaft
Installed Distance
Bearing No.
Figure 5-121
1 Protruding 12 - 14 mm
13. Hold the drift with the new bearing against the 2 150 - 152 mm
old. Tighten the flange nut against the cylinder
3 314 - 316 mm
(Figure 5-121).
Figure 5-122
4 478 - 480 mm
5 642 - 644 mm
6 806 - 808 mm
7 970 - 972 mm
Note: The new bearing will reach the correct

position before the old bearing is
completely released. The drift will
protrude out of the block when installing
No. 1 bearing as shown in Figure 5-122.
0002351
Figure 5-122

12/05
Replace the Camshaft Bearings - 8SY

Figure 5-124
1. Remove camshafts. See Remove the Camshaft

on page 5-70.
2. Wipe all residue from the bearing bores and the
edges of the old bearings.
Figure 5-126
Figure 5-124
15. Carefully tap the old bearing with a plastic
hammer to release it (Figure 5-124).
16. Retract the cylinder.
17. Remove the press drift.
18. Check that the bearing oil holes are aligned
with the cylinder block oil ports.
Note: The bores for camshaft bearings No. 2, 4
and 6 have two oil ports. The others only
have the lower port.
Figure 5-125
Figure 5-125
19. Repeat the procedure for the remaining
bearings (Figure 5-125). Figure 5-126
20. Remove all old gasket material from front 3. Attach flange (OEM Part No. 99 373) to
camshaft cover and the associated area on the hydraulic cylinder (OEM Part No. 99 003)
cylinder block. NOTICE: The sealing surfaces (Figure 5-126).
must be absolutely clean and free from grease.
Do not touch the surfaces after degreasing. 4. Align spacer (OEM Part No. 99 519) and attach
flange and cylinder to cylinder block with bolts.
21. 6SY Engines: Install camshaft cover on front of
cylinder block using new gasket. 5. Insert bar through hydraulic cylinder until the
outer hole in bar is behind the bearing to be
22. Install camshaft. See Install the Camshaft on removed.
page 5-78.


6. Secure drift (OEM Part No. 99 516) in the outer 8. Connect the hydraulic cylinder to the hydraulic
hole on the bar using a 12.9 M8 screw (Figure pump. Run the hydraulic pump until the bearing
5-127). has become completely removed from the bore
Figure 5-128
(Figure 5-129).
Figure 5-130
Figure 5-128
7. Pull the bar until the drift is locked in the
bearing. Attach the socket next to the hydraulic
cylinder using an 8 mm (3/16 in.) pin punch
(Figure 5-128).
Figure 5-130
9. Remove the drift from the bar (Figure 5-130).
Remove the bearing.

12/05
10. Ensure the bearing bore is clean. Release the

Figure 5-132
hydraulic cylinder and push the bar back

through the bearing bore. NOTICE: The bearing
must be installed in the correct direction. The
right camshaft must have the notch in the
bearing facing the direction of the water pump.
The left camshaft must have the notch in the
bearing facing the direction of the flywheel.
Figure 5-131
Figure 5-132
12. Attach drift (OEM Part No. 99 516) to the outer
hole on the bar with a 12.9 M8 bolt. Ensure the
lubrication hole faces upwards (Figure 5-132).
NOTICE: Ensure the notch in the bearing is
facing the correct direction and the lubrication
hole is up.
Figure 5-133
Figure 5-131
11. Put a new bearing on drift (OEM Part No. Figure 5-133
99 516). Ensure that the ball on drift engages
the round bearing lubrication hole correctly
(Figure 5-131). Lubricate the bearing
externally.

13. Pull the bar through the hydraulic cylinder until Install the Camshaft
socket (OEM Part No. 99 517) can be locked
onto it using an 8 mm (3/16 in.) pin punch. The NOTICE: 8SY engines: The left camshaft has
pin punch must point vertically so that the provisions for mounting a gear to each end. The
lubrication hole is correctly located (Figure end having five M10 threaded holes must be
5-133). installed toward the rear of the engine.
14. Pull the bearing into position until the distance 1. Remove all old gasket material and sealing
from the front face of the cylinder block and the compound from camshaft covers, front
front edge of the drift is at the specified camshaft cover, timing gear plate, flywheel
distance. Check that the drift is still vertical housing and all associated areas on the
when the bearing is in position. cylinder block.
Note: The drift will protrude out of the block 2. Lubricate all camshaft bearings, journals and
when installing No. 1 bearing. lobes with clean engine oil.
Figure 5-134
3. Carefully install camshaft taking care not to
damage the lobes or bearings.
4. Install guide flanges.
Figure 5-135
Figure 5-134
15. Check that the lubrication hole is open by
looking or by probing with something such as a
spray lubricant straw or wire (Figure 5-134).
Camshaft Bearing Installed Specifications -
8SY Engines
Camshaft
Installed Distance
Bearing No.
1 Protruding 13 mm
2 196 mm
3 400 mm
0002355
4 603 mm
Figure 5-135
5 811 mm
16. Replace the remaining bearings in the same

way.

12/05
5. 6SY Engines: Apply sealing agent (OEM Part 9. Install camshaft gear(s). See Camshaft Gear on
No. 816 064 or equivalent) to cylinder block in page 5-67.
the pattern shown (Figure 5-135). The bead 10. Install intermediate gear(s). See Intermediate
width should be 0.8 - 1.2 mm (0.032 - 0.047 Gear on page 5-62.
in.). NOTICE: Ensure that sealing agent is
applied inside the bolt holes, but without 11. Install flywheel housing. See Install the
allowing sealing agent into the crankcase. Flywheel Housing on page 5-53.
Excess sealing agent may block channels and 12. Install flywheel. See Install the Flywheel on
nozzles, particularly around oil passages. page 5-54.
Assembly must be completed within 25 minutes Figure 5-138
of the beginning of sealant application.

Figure 5-136
0002342
0002356
Figure 5-138
Figure 5-136 13. Lubricate valve tappets with clean engine oil
and install in original locations. Tighten banjo
6. 6SY Engines: Install timing gear plate on bolts to 32 N·m (24 ft-lb) (Figure 5-138).
engine block. Tighten the bolts to 63 N·m NOTICE: The sealing surfaces must be
(46 ft-lb). absolutely clean and free from grease. Do not
touch the surfaces after degreasing.
Figure 5-137
14. Install camshaft covers using new gaskets.

15. 8SY Engines:
(a) Install the fuel manifolds. Tighten bolts to
26 N·m (230 in.-lb).
(b) Install the coolant recovery tank and
catwalk.
(c) Install the connection pipe(s) between the
charge air cooler and turbocharger.
(d) Install the connection pipe between the
charge air coolers.
16. Install the centrifugal oil cleaner assembly.
Figure 5-137
17. Install lower rocker covers, valve bridges, push
7. 8SY Engines: Install front camshaft gear. rods and rocker shaft assemblies. See Remove
Tighten bolts to 63 N·m (46 ft-lb). and Install Rocker Covers on page 5-23.
8. 8SY Engines: Install front gear housing. See 18. Check valve timing to verify installation. See
Install the Front Gear Housing - 8SY on Check the Camshaft Timing on page 5-60.
page 5-62.

19. Check and adjust valve and unit injector

clearances. See Adjust Valve and Unit Injector
Clearances on page 5-18.
20. Install upper rocker covers. See Remove and
Install Rocker Covers on page 5-23.

12/05

ENGINE Cylinder Block and Crankshaft
CYLINDER BLOCK AND CRANKSHAFT

Figure 5-1398SY Engine Shown
(3)
(4)
(2) (5)
(7)
(1)
(6) (8)
(7)
(16)
(11)
(13)
(12)
(9)
(13)
(10)
(14)
(15)
0003061

Cylinder Block and Crankshaft ENGINE
12/05
1 – Side Cover (1 each side)

2 – Gasket
3 – Oil Cooler Assembly
4 – Tappet Cover (4 used)
5 – Gasket
6 – Plug
7 – O-Ring
8 – Cylinder Liner
9 – Crankshaft
10 – Thrust Bearing (4 used)
11 – Piston Cooling Nozzle (4 used)
12 – Main Bearing Cap Side Bolt
13 – Main Bearing Insert
14 – Main Bearing Cap
15 – Main Bearing Bolt
16 – Camshaft Bearing
Figure 5-139
Note: Service procedures for 6SY and 8SY engines are similar, therefore graphics shown will be
representative and might not match the engine being serviced.

Remove the Crankshaft Specifications

1. Remove front crankshaft seal housing. Inspection Item Engine Specification
2. Remove spacer sleeve and crankshaft damper Crankshaft End 6SY 0.18 - 0.37 mm
from crankshaft. Play (0.007 - 0.015 in.)
8SY 0.138 - 0.380 mm
3. Remove flywheel. See Remove the Flywheel on (0.0054 - 0.0150 in.)
page 5-51.
4. Remove flywheel housing. See Remove the 11. Measure bearing oil clearance to help
Flywheel Housing on page 5-53. determine extent of wear. See Measure the Oil
5. Remove crankshaft gear. See Crankshaft Gear Clearance on page 5-85.
on page 5-69. Figure 5-141
6. Remove cylinder heads. See Remove the

5

7. Remove oil sump, oil suction pipe and strainer 5
and the oil pump. See Oil Pump on page 8-14.

8. Remove piston cooling nozzles.
9. Remove pistons and connecting rods. See (1)
Remove and Disassemble Piston and
Connecting Rod on page 5-37.
10. Before removing main bearing caps, measure
crankshaft end play. Figure 5-141
Figure 5-140
Note: The main bearing caps (Figure

5-141, (1)) are marked and must be
installed in their original locations.
Main bearing caps on 8SY engines are

bolted through both the bottom and side
of the engine block.
12. Remove the crankshaft bearing caps and main
(1)
bearing inserts.
(2)
0001961
Figure 5-140
• Mount a dial indicator (Figure 5-140, (1)) on
the cylinder block. Move the crankshaft (Figure
5-140, (2)) in and out to measure end play.

12/05
Measure the Oil Clearance

Figure 5-142
Oil clearance should be checked during

disassembly to determine the extent of wear and
during reassembly to ensure long engine life. The
same procedure is done for both connecting rods
and main bearings.
1. Remove the bearing cap. Do not remove the
bearing inserts at this time.
2. Wipe oil from the bearing insert and crankshaft
journal surfaces.
Figure 5-143
(1)
0002357
0001898
Figure 5-143
3. Place a piece of PLASTIGAGE® (Figure

5-143, (1)) along the full width of the bearing
insert.
Note: Do not rotate crankshaft when using
PLASTIGAGE. A false reading may
result.
4. Install the bearing cap and tighten to
specification. See Special Torque Chart on
page 5-9.
5. Remove the bearing cap.
Figure 5-142
13. Lift out the crankshaft (Figure 5-142).

Figure 5-144 2. Measure the outside diameter of each crankpin

(Figure 5-145, (2)) and main bearing journal
(Figure 5-145, (1)). Take measurements at
several places around each bearing surface. If
(1) not within specification, grind the journals and
install undersize bearings, or replace the
crankshaft.
Crankshaft Specifications
0001899
Main Bearing
Figure 5-144 6SY and 8SY
Journals
6. Compare the width of the flattened Standard 107.978 - 108.000 mm
PLASTIGAGE to the graduation marks on the Diameter (4.2511 - 4.2520 in.)
package (Figure 5-144, (1)). The mark that Undersize 1 107.728 - 107.750 mm
most closely matches the width of the flattened Diameter (4.2412 - 4.2421 in.)
PLASTIGAGE will indicate the bearing oil Undersize 2 107.428 - 107.450 mm
clearance. Diameter (4.2294 - 4.2303 in.)
7. Repeat with the remaining bearings. Undersize 3 107.228 - 107.250 mm

Diameter (4.2216 - 4.2224 in.)
Inspect the Crankshaft Undersize 4 106.978 - 107.000 mm
Diameter (4.2117 - 4.2126 in.)
1. Use the color check method or Magnaflux to Oil Hole Radius 4.75 - 4.85 mm
inspect the crankshaft for cracks. Replace the (0.187 - 0.191 in.)
crankshaft if evidence of fractures are found. Surface Quality 0.25 Ra
Figure 5-145
Connecting Rod
6SY and 8SY
Journals
Standard Diameter 86.978 - 87.000 mm
(3.4247 - 3.4252 in.)
Undersize 1 86.728 - 86.750 mm
Diameter (3.4247-3.4153 in.)
Undersize 2 86.478 - 86.500 mm
Diameter (3.4046 - 3.4055 in.)
Undersize 3 86.228 - 86.250 mm
Diameter (3.3948 - 3.3957 in.)
Undersize 4 85.978 - 86.000 mm
Diameter (3.3850 - 3.3858 in.)
Hole Recess 4.8 - 5.2 mm
R Radius (0.189 - 0.205 in.)
Surface Quality 0.25 Ra (roughness average)
R Maximum Width 56.05 mm (2.207 in.)
Oil Clearance 0.051 - 0.114 mm
(0.0020-0.0045 in.)
(1)
(2) 0001733A
Figure 5-145

12/05
Inspect the Cylinder Block

Thrust
6SY and 8SY
Bearing
Reconditioning
Standard 3.37 - 3.43 mm (0.133 - 0.135 in.)
Thickness Heat arising from the main bearings seizing and
Oversize 1 3.45 - 3.51 mm (0.136 - 0.138 in.)
rotating in the cylinder block will change the
Thickness properties of the material in the cylinder block.
Oversize 2 3.50 - 3.56 mm (0.138 - 0.140 in.)
These cylinder blocks must be discarded.
Thickness
If the main bearing seizes but does not rotate in the
Oversize 3 3.63 - 3.69 mm (0.143 - 0.145 in.)) cylinder block, the cylinder block can be
Thickness
overhauled. The main bearing bore roundness
Oversize 4 3.88 - 3.94 mm (0.153 - 0.155 in) must be within specifications. Machining
Thickness
out-of-round main bearing seats is not
End Play 0.138 - 0.380 mm (0.0054 - 0.0149 in.) recommended.
Recondition the Crankshaft Figure 5-147
If any the crankshaft journals do not meet

specifications, it may be possible to grind any or all
of them to an undersize. The connecting rod
bearings, main bearings and thrust bearing inserts
are available undersize. If the journals are ground
undersize, the finishing standards must be adhered
to. 4
Checking and Grinding

• When regrinding, stated undersizes must be
complied with. Suitable bearings are available for 3
1
these sizes.
2 0002360
Figure 5-146
(4)
(3)
Figure 5-146
• It is important that the fillet radius of the journals (2)
is correct (Figure 5-146).
• After grinding the journals, the oil hole should be (1)
B113584A
rounded off and polished. Figure 5-147

1. Remove all main bearing inserts. Ensure the Install Crankshaft

bearing seating surfaces are free of any debris.
Install the main bearing caps and tighten to NOTICE: Ensure the bearing inserts and bearing
50 N·m (37 ft-lb) plus 90°. mounting surfaces are absolutely clean and free of
oil.
2. Measure the diameter of each main bearing
Figure 5-149
bore at four different positions (Figure 5-147).

Specifications
Main Bearing Bore Diameter
Standard 112.200-112.222 mm
(4.4173-4.4182 in.)
Out-of-Round 0.016 mm (0.0006 in.)
(Maximum)
3. Ensure that oil passages are clear and

unobstructed.
4. Check for discoloration or evidence of cracks. If
a fracture is suspected, use the color check
method or the Magnaflux method to determine Figure 5-149
if the cylinder block is fractured.
Figure 5-148
1. Install the main bearing inserts in the cylinder
a 20 mm block and main bearing caps. Apply a generous
(0.75 in.) amount of clean engine oil (Figure 5-149) to
d
e the bearing inserts and crankshaft journals.
b Ensure all oil holes are properly aligned.
2. Install thrust bearings.
c Figure 5-150
20 mm
(0.75 in.) 0000230B
Figure 5-148
5. Measure cylinders for roundness, taper, and
inspect for evidence of scoring. Consider
honing or replacing the damaged liner(s) if the
measurements are not within specification.
6. Take measurements at three places (a, b, c),
and in two directions (d and e) in each cylinder.
Figure 5-150
3. Carefully lower the crankshaft into place.
NOTICE: The main bearing caps are marked
and must be installed in their original positions.

12/05
0002362
5 (1)
Figure 5-152
5
6. Install crankshaft gear and temporarily retain

using two flywheel bolts (Figure 5-152, (2)) and
50 mm (2 in.) spacers (Figure 5-152, (1)).
(2)
Ensure the timing marks are aligned. See
Crankshaft Gear on page 5-69.
7. Install pistons and connecting rods. Install
piston cooling nozzles. See Install the Piston
Figure 5-151 and Connecting Rod on page 5-45.
4. Install main bearing caps. Lubricate and tighten 8. Install oil pump, oil suction pipe with strainer
bearing cap bolts (Figure 5-151, (1)) to and the oil sump. See Oil Pump on page 8-14.
specification. 9. Install spacing sleeve on crankshaft journal.
5. 8SY: Lubricate and install main bearing side Install driver and crankshaft damper. Tighten to
bolts (Figure 5-151, (2)) and tighten to 135 N·m (100 ft-lb).
specifications. 10. Install new seal in front cover/housing. See
Main Bearing Bolt Torque Replace the Front Crankshaft Seal on
page 5-90.
Item 6SY 8SY
11. Install front seal housing using a new gasket.
S/N: 6 513 632 and
before:
See Install the Front Gear Housing - 8SY on
50 N·m (37 ft-lb) plus page 5-62.
Main Bearing 90° 90 N·m (66 ft-lb) 12. Install belt pulley and tighten bolts to:
Cap Bolts
S/N: 6 513 633 and plus 90°
(torque-turn) • 6SY: 110 N·m (81 ft-lb)
later:
200 N·m • 8SY: 92 N·m (68 ft-lb)
(148 ft-lb) plus 90°
Main Bearing - 180 N·m Flywheel Housing on page 5-53.
Side Bolts (133 ft-lb)
page 5-54.
15. Install cylinder heads. See Install the Cylinder
Head on page 5-34.

Replace the Front Crankshaft Seal

Figure 5-155
1. Remove belt(s), crankshaft damper and belt

pulley. NOTICE: 8SY engines: The crankshaft
seal seals against the hub of the belt pulley.
Use care not to damage the sealing surface of
pulley (Figure 5-153).
Figure 5-153
Figure 5-155
3. Pull or pry seal from the cover (Figure 5-155).
B01_6379A
Take care to avoid damaging the seal mounting
surface in the cover.
Figure 5-153
Figure 5-154
4. Wipe the sealing surface in the cover clean.
Figure 5-156
(1)
(2)
(3)
(4)
(1)
(5)
1 – Washer
2 – Pulley
3 – Driver
4 – Spacing Sleeve
5 – Seal
Figure 5-154 0002366
2. 6SY: Remove driver bolts and remove driver

(Figure 5-154, (3)). Use care not to damage
the sealing surface of driver.

Exhaust Manifold ENGINE
12/05
EXHAUST MANIFOLD
Replacing Gaskets
1. WARNING! Make sure that all connections
are tightened to specifications after repair is
made to the exhaust system. Remove the
bolts between the exhaust manifold and the
turbocharger connection pipe.
2. Remove the bolts and remove the exhaust
(1) manifold.
3. Scrape away the gaskets from the exhaust
manifolds and cylinder head.
4. Lubricate the joints with heat-resistant grease
and install new gaskets.
Figure 5-156
5. Install new O-rings in the water seals.
5. NOTICE: The crankshaft seal must be installed 6. Install the water-cooled exhaust manifold.
dry and must not be lubricated. The sleeve in Tighten bolts to:
the seal should be left in place until the seal is
installed. Place new seal on seal installer • 6SY: 59 N·m (44 ft-lb)
(Figure 5-156, (1)) and press in place by • 8SY: 63 N·m (46 ft-lb)
tightening the bolts alternately. The seal is 7. Install new O-rings and seal. Connect the
correctly installed when the tool contacts the turbocharger pipe. Tighten the bolts to 63 N·m
cover. (46 ft-lb).
6. Remove the tool by threading the bolts into the
threaded holes of the special tool.
7. Wipe clean the sealing surface of the driver
(6SY) or belt pulley (8SY).
8. 6SY: Install a new seal on the end surface of
the driver and push the driver onto the spacing
sleeve on the end of the crankshaft.
9. 6SY: Install the driver to the crankshaft flange
and tighten the flange bolts to 135 N·m
(100 ft-lb).
10. 6SY: Install crankshaft damper and belt pulley.
Tighten to 110 N·m (81 ft-lb).
11. 8SY: Install belt pulley. Tighten to 92 N·m
(68 ft-lb).
12. Install belt(s). See Replace Alternator Belt on
page 11-9 for the correct belt routing.

ENGINE Lifting the Engine
LIFTING THE ENGINE 10. Fasten lifting chain (OEM Part No. 98 094)
(Figure 5-157, (1)) to the rear lifting eyes.
6SY Engines DANGER! ALWAYS use lifting equipment
with sufficient capacity to lift the marine
1. Disconnect negative (-) battery cable. engine. Additional equipment is necessary
2. Drain engine oil and coolant. to lift the marine engine and marine gear
3. Detach engine from reverse gear. together.
4. Detach the pipe between the seawater pump DANGER! NEVER stand under hoisted
and heat exchanger. Remove the seawater engine. If the hoist mechanism fails, the
pump. engine will fall on you, causing death or
serious injury. CAUTION! Avoid injury or
5. Remove turbocharger oil pipes. equipment damage due to engine falling.
6. Remove starter motor wiring and alternator ALWAYS secure the engine solidly to prevent
wiring. the engine from falling during service.
7. Remove wiring to the control unit. 11. Fasten lever block (OEM Part No. 587 308)
8. Remove fuel connection. See Replace the Fuel (Figure 5-157, (2)) to the front lifting eye.
Feed Pump on page 6-13. 12. Disconnect all engine mounts. NOTICE: The
9. Disconnect pipe to the gearbox cooler or lifting eyes are designed for a maximum
reversing gear oil cooler. inclination angle of 30° when lifting the engine.
(2)
(1)
0002367
Figure 5-158
13. Carefully lift engine using the lever block to
adjust the angle of the engine (Figure 5-158).
DANGER! NEVER stand under hoisted
marine engine. If the hoist mechanism fails,
the marine engine will fall on you.
14. Place engine on suitable engine support or
attach to an engine repair stand of sufficient
weight capacity. WARNING! ALWAYS secure
the engine solidly to prevent injury or
damage to parts due to the engine falling
0002683
during work on the engine.
Figure 5-157
8SY Engines
1. Disconnect negative (-) battery cable.
2. Drain engine oil and coolant.

Attaching Engine to Repair Stand ENGINE
12/05
3. Detach engine from reverse gear. ATTACHING ENGINE TO

4. Detach the pipe between the seawater pump REPAIR STAND
and heat exchanger. Remove the seawater
pump. When attaching and engine to a repair stand, be
5. Remove turbocharger oil pipes. sure to use a stand of adequate capacity to safely
support the engine to be repaired and that it is
6. Remove starter motor wiring and alternator attached to the engine. CAUTION! Avoid injury or
wiring. equipment damage due to engine falling.
7. Remove wiring to the control unit. ALWAYS secure the engine solidly to prevent
8. Remove fuel connection. See Replace the Fuel the engine from falling during service.
Feed Pump on page 6-13.
9. Disconnect connecting pipe to the gearbox
cooler or reversing gear oil cooler.
10. Attach two lifting eyes (OEM Part No.
1 360 442) (or similar tool) onto the flywheel
housing over the center in the 10 o’clock to
2 o’clock position.
11. Fasten lifting chain (OEM Part No. 98 094) to
the rear lifting eyes.
12. Fasten lever block (OEM Part No. 587 308) to
the front lifting eye. NOTICE: The engine lifting
eyes are sized for lifting the engine only, not the
engine together with connected equipment
(gearbox, reverse gear, etc.) or frame. All three
lifting eyes must be used.
13. Disconnect all engine mounts. NOTICE: The
lifting eyes are designed for a maximum
inclination angle of 20° when lifting the engine.
14. Carefully lift engine using the lever block to
adjust the angle of the engine.
15. Place engine on suitable engine support or
attach to an engine repair stand of sufficient
weight capacity. WARNING! ALWAYS secure
the engine solidly to prevent injury or
damage to parts due to the engine falling
during work on the engine.

ENGINE Attaching Engine to Repair Stand

Section 6
FUEL SYSTEM
Page
Introduction...................................................................................... 6-3
Specifications .................................................................................. 6-4
Special Service Tools...................................................................... 6-5
Fuel System Components ............................................................... 6-6
Fuel Delivery Components ........................................................ 6-6
Fuel Injector Components ......................................................... 6-7
Tests and Adjustments.................................................................... 6-7
Adjust the Unit Injectors............................................................. 6-7
Measure the Fuel Feed Pump Pressure.................................... 6-7
Test the Fuel Pressure Relief Valve .......................................... 6-8
Repair.............................................................................................. 6-8
Remove the Unit Injector ........................................................... 6-8
Install the Unit Injector ............................................................. 6-11
Replace the Fuel Feed Pump.................................................. 6-13
Replace the Fuel Filter and Fuel Filter / Water Separator ....... 6-14
Replace Return Fuel Line........................................................ 6-15
Bleed the Fuel System ............................................................ 6-17

FUEL SYSTEM

Safety Precautions FUEL SYSTEM
12/05
SAFETY PRECAUTIONS INTRODUCTION

This section of the Service Manual describes the
procedures necessary to remove, install, and adjust
Fire Hazard the PDE31 and PDE32 unit injectors and their
Diesel fuel is flammable and explosive associated system components as used on the
under certain conditions. NEVER put Yanmar 6SY and 8SY engines.
diesel fuel or other flammable material
such as oil, hay or dried grass near the
engine during engine operation or shortly after
shutdown.
Never use a shop rag to catch the fuel.
ALWAYS put an approved fuel container under the

opening whenever you remove any fuel system
component (such as changing the fuel filter).
Dispose of waste properly.
Wipe up all spills immediately.
High-Pressure Hazard
Avoid injury from escaping fuel under
pressure. NEVER check for a fuel leak
with your hands. ALWAYS use a piece
of wood or cardboard.

FUEL SYSTEM Specifications
SPECIFICATIONS
Inspection Item Specification Reference Page
PDE31 Unit Injector Height 66.8 - 67.0 mm See Adjusting Unit
(2.63 - 2.64 in.) Injectors on page 5-19
PDE32 Unit Injector Height 69.8 - 70.0 mm
(2.75 - 2.76 in.)
Fuel Pressure Minimum at 500 rpm 4.5 bar (65 psi) See Measure the Fuel
Minimum at 1900 rpm 5.5 bar (80 psi) Feed Pump Pressure
on page 6-7
Fuel Pressure Relief Minimum (Hand Pumping) 4.5 bar (65 psi) See Test the Fuel
Valve Pressure Maximum at 1500 rpm 7.5 bar (109 psi) Pressure Relief Valve
on page 6-8
Return Line Tubing 6 mm OD Minimum Internal 35 mm (1.38 in.) See Replace Return
12 mm OD Diameter of Bend 95 mm (3.74 in.) Fuel Line on page 6-15
Special Torque Chart

Lubricating Oil
Application (Thread
Component Tightening Torque Reference Page
Portion and Seat
Surface)
Rocker Arm Adjusting Screw Locknut 39 N·m (29 ft-lb) - See Adjust Valve and
Unit Injector
Clearances on
page 5-18
Rocker Arm Shaft Bolt 105 N·m (77 ft-lb) Not Applied See Install the Unit
Unit Injector Fork Clamp Bolt (torque-turn) 20 N·m (133 in.-lb) plus Not Applied Injector on page 6-11
75°
Injector Electrical Terminal Screw 2 N·m Not Applied
(283 in.-oz)
Rocker Cover Bolt (Upper and Lower Cover) 26 N·m (19 ft-lb) Not Applied
Return Line Nut 6 mm OD Tubing 10 N·m (89 in.-lb) - See Replace Return
12 mm OD Tubing 20 N·m (177 in.-lb) - Fuel Line on page 6-15

Special Service Tools FUEL SYSTEM
12/05

numbers are referred to as Yanmar Part No. and Scania part numbers are referred to as OEM Part
No. Tools not having part numbers must be acquired locally.

1 Unit Injector OEM Part No. 99 414 - PDE31
Adjustment Tool OEM Part No. 99 442 - PDE32
(For Adjusting
Unit Injectors)
0002672
2 Flywheel Turning OEM Part No. 99 309

Tool
0002660
3 Slide Hammer OEM Part No. 87 596

(For Removing
Unit Injectors)
0002655
4 Fuel Pressure OEM Part No. 98 113

98 113
Gauge (For
Measuring Fuel
System
Pressure)
00 1572
5 Torque OEM Part No. 288 179
Screwdriver (For
Connecting
Cables to
Injector)

FUEL SYSTEM Fuel System Components
FUEL SYSTEM COMPONENTS

Fuel Delivery Components
Figure 6-16SY Engines Figure 6-28SY Engines
(8)
(7)
(6) (7)
(5)
(7)
(9) (6)
(5)
(10) (5)
(8)
(5)
(4) (3) (2)
(1)
(3)
(2) (3)
0002702
(4)
(9)
1 – Fuel Supply Line
2 – Fuel Feed Pump 0002705
3 – Fuel Supply to Filter (1)

4 – Fuel Filter
5 – Fuel Supply to Fuel Manifold 1 – Fuel Supply Line
6 – Fuel Manifold 2 – Fuel Feed Pump
7 – Gasket 3 – Fuel Supply to Filter
8 – Bleeder Valve 4 – Fuel Filter
9 – Banjo Bolt 5 – Fuel Supply to Left Fuel Manifold
10 – Fuel Return Line 6 – Fuel Manifold (2 used)
7 – Bleeder Valve
Figure 6-1 8 – Fuel Leak-Off Line
9 – Fuel Return Line
Figure 6-2

Tests and Adjustments FUEL SYSTEM
12/05
Fuel Injector Components TESTS AND ADJUSTMENTS

Figure 6-3
(4) (5) NOTICE: All work that involves opening the fuel
system must be completed as follows:
(3) • Bleed the system. See Bleed the Fuel System on

page 6-17.
(6)
(2) • Start engine and check for leaks. Allow engine to
run until it is running smoothly.
(1)
(7)
• Check and delete any fault codes that are
registered in the control unit after the work has
(8)
been completed.
Adjust the Unit Injectors

(9)
Unit injectors and valves should be adjusted at the
same time. See Adjust Valve and Unit Injector
(12) Clearances on page 5-18 for procedures.
(10)
(11)
Measure the Fuel Feed Pump
0002700 Pressure
1 – Unit Injector Assembly Procedure
2 – Ball
3 – Link 1. Replace fuel filter and bleed fuel system before
4 – Rocker Arm measuring.
5 – Jam Nut Figure 6-4
6 – Adjusting Screw
7 – Pushrod
8 – Clamp Fork Bolt
9 – Clamp Fork
10 – Roller Tappet
11 – Gasket
12 – O-Ring
Figure 6-3
Figure 6-4
2. Connect a pressure gauge to the fuel filter
outlet connection as shown in Figure 6-4.
3. Start engine and set speed to 500 rpm. Read
and record pressure.
4. Increase engine speed to 1900 rpm. Read and
record pressure.

FUEL SYSTEM Repair
Specifications REPAIR
Inspection Item RPM Pressure (Min.) NOTICE: All work that involves opening the fuel
Fuel Feed Pump 500 rpm 4.5 bar (65 psi) system must be completed as follows:
Pressure 1900 rpm 5.5 bar (80 psi)
• Bleed the system. See Bleed the Fuel System on
page 6-17.
Results
• If pressure reading is below specification, inspect • Start engine and check for leaks. Allow engine to
fuel line connections, pressure relief valve, fuel run until it is running smoothly.
filter and feed pump. • Check and delete any fault codes that are
Test the Fuel Pressure Relief Valve been completed.
Procedure Remove the Unit Injector
Figure 6-5
1. Disconnect the battery(s), negative (-) cable

first.
2. Shut off all valves in the fuel supply system.
CAUTION! Ensure that no fuel enters the
cylinder from the disconnected fuel system
components. If fuel runs into the
combustion chamber, it must be removed
immediately using a pump.
Figure 6-5 (1)
1. Connect a pressure gauge to the fuel filter

outlet connection as shown in Figure 6-5
2. Turn the key switch to the ON position. Do not
start the engine at this time.
3. Operate the hand pump while reading the
pressure gauge. Read and record pressure.
4. Start the engine and increase the speed to
1500 rpm. Read and record pressure.
(2)
Specifications
3:5829A
Inspection Item RPM Pressure

Fuel Pressure Hand-Operated 4.5 bar (65 psi) (Min.)
Relief Figure 6-6
1500 rpm 7.5 bar (109 psi) (Max.)
Results
• If test pressure reading is not within
specifications, the fuel pressure relief valve must
be replaced.

Repair FUEL SYSTEM
12/05
Figure 6-78SY Engines 6. Remove bolts (Figure 6-8, (1)) retaining the
rocker arm shaft. Alternately loosen each bolt
(1)
until valve tension is relieved. WARNING!
Never lean over the engine when removing
the rocker arm shaft. The unit injector
(1)
spring is under considerable tension and
can unexpectedly come loose, causing
personal injury.
Figure 6-9
(3) (1)
(2)
0002705B
Figure 6-7
3. Open bleeder valve(s) (Figure 6-6, (1)) or
(Figure 6-7, (1)) and drain fuel system by
loosening banjo bolt (Figure 6-6, (2)) or
(Figure 6-7, (2)) on opposite end of fuel
manifold. On 8SY engines, also loosen union Figure 6-9
(Figure 6-6, (3)) or (Figure 6-7, (3)).
4. Clean rocker cover and surrounding area. Note: If the spring comes loose from the unit
injector, the unit injector must be
5. Remove upper rocker cover. See Remove and replaced.
Figure 6-8
7. Remove rocker arm shaft assembly (Figure
6-9, (1)). CAUTION! Identify all parts and
their location using an appropriate method.
It is important that all parts are returned to
the same position during the reassembly
process.
Figure 6-8

FUEL SYSTEM Repair
10. Remove one lower rocker cover bolt (Figure

Figure 6-10
6-12, (1)) to provide easier positioning of the

(1)
slide hammer. NOTICE: If the slide hammer is
placed directly under the solenoid valve, there
(2) is a risk of breaking the solenoid valve.
Figure 6-13
(3)
Figure 6-10
1 – Fork Clamp
2 – Fork Clamp Bolt
3 – Unit Injector
8. Remove unit injector fork clamp bolt (Figure
6-10, (2)) and fork clamp (Figure 6-10, (1)). Figure 6-13
Figure 6-11
11. Rotate unit injector counterclockwise until it

stops. Position slide hammer under solenoid
valve at the approximate location (Figure 6-13).
NOTICE: Never lift the unit injector by the
spring. The spring can come loose resulting in
the need to replace the unit injector.
Figure 6-14
Figure 6-11
9. Disconnect electrical wires from unit injector.
The screws cannot be removed (Figure 6-11).
Figure 6-12
(1) 0002278
Figure 6-14
12. Remove unit injector using a slide hammer. If
unit injector is stuck, tap carefully with rubber
mallet on the solenoid valve housing (Figure
6-14).
Figure 6-12 13. If injector gasket did not come out with injector,
remove it from the bottom of the injector seat.
NOTICE: The unit injector must not be
disassembled. Replace the entire unit as
necessary.

Repair FUEL SYSTEM
12/05
Install the Unit Injector

Figure 6-16
1. Make sure that the old gasket is not at the

bottom of the injector seat. Clean the sealing
surfaces in the injector seat.
Figure 6-15
(5)
0002701 7/20
(4)
(3)
(6)
Figure 6-16
4. Place the bolt in the fork clamp. Place the fork
(7) clamp in position on the unit injector and insert
the injector into the cylinder head. Press the
(2) unit injector down by hand as far as possible
(Figure 6-16). NOTICE: NEVER hit the unit
(1) 0002701
injector spring with a mallet. Doing so will
disengage the spring retainer and render the
1 – Gasket injector unusable.
2 – O-Ring Figure 6-17
3 – Unit Injector
4 – Ball
5 – Link
6 – Bolt
7 – Fork Clamp
Figure 6-15
2. Lubricate the unit injector O-rings with O-ring
grease (OEM Part No.1 402 039 or equivalent).
NOTICE: Always install new O-rings and
sealing washer when installing a unit injector.
Make sure all sealing surfaces are clean.
3. Install new gasket on unit injector. The rubber
insert of the gasket will keep gasket in place on
the unit injector.
Note: Ensure fork clamp and bolt are dry and
free of oil. Figure 6-17
5. Torque-turn tighten the bolt to 20 N·m
(133 in.-lb) plus an additional 75°. There are
two marks (Figure 6-17, (A and B)) on the
lower rocker cover with a 75° angle between
them.

FUEL SYSTEM Repair
NOTICE: Ensure injector wire terminals are

Figure 6-18
installed with the bosses (Figure 6-19, (1))

facing up.
Figure 6-20
6. Install the rocker shaft and rockers. Tighten the 9. Connect wires on the unit injectors. Their
bolts to 105 N·m (77 ft-lb). relative position is not important. Use torque
7. Ensure the pushrods are in their correct screwdriver 588 179 (or similar tool) to tighten
positions, including the injector ball and link. screws to 2 N·m (283 in.-oz) (Figure 6-20).
Ensure the unit injector pushrod is firmly NOTICE: Tighten screws to correct torque. The
secured in its lower position by the retaining entire unit injector must be replaced if screws
ring (Figure 6-18). shear off due to over tightening.
8. Adjust the unit injector. See Adjust Valve and 10. Install upper rocker cover and tighten bolts to
Unit Injector Clearances on page 5-18. 26 N·m (19 ft-lb). See Remove and Install
Figure 6-19
Rocker Covers on page 5-23.
(1)
(1)
(2)
118 482A
3:5829A

Repair FUEL SYSTEM
12/05
(1)
(1)
(3)
(2)
0002705B
Figure 6-22
11. Close bleeder valve(s) (Figure 6-21, (1)) or
(Figure 6-22, (1)) and tighten banjo bolt(s)
(Figure 6-21, (2)) or (Figure 6-22, (2)).
12. Turn on fuel supply valves. Figure 6-23
13. Fill and bleed fuel system. See Bleed the Fuel
System on page 6-17.
14. Connect the battery(s), negative (-) cable last.
15. Start the engine and check for fuel leaks. Allow
the engine to run until it is running smoothly.
16. Check and delete any fault codes that are
been completed. See Fault Codes on
page 13-18.
Replace the Fuel Feed Pump

first.
2. Shut off all valves in fuel supply system.
3. Clean outside of fuel feed pump.
0002704
Figure 6-24

FUEL SYSTEM Repair
4. Remove supply and pressure lines from fuel 2. Operate the hand pump until resistance is felt
feed pump. Install caps or plugs on all open and the fuel begins to flow from the pipe.
fittings to prevent contamination of the fuel 3. If pump still refuses to prime: Disconnect the
system. feed pump outlet pipe (Figure 6-25, (2)). Pump
5. Remove two bolts and remove the fuel feed until fuel begins to run out of the pipe.
pump. 4. Bleed the fuel system. See Bleed the Fuel
6. Place a new O-ring onto the fuel feed pump and System on page 6-17.
lubricate with O-ring grease (OEM Part
No.1 402 039 or equivalent). Replace the Fuel Filter and Fuel
7. Install fuel feed pump. Filter / Water Separator
8. Connect the suction and pressure lines.
Replace the Fuel Filter
9. Bleed fuel system. See Bleed the Fuel System Figure 6-26
on page 6-17. (1)

10. Start the engine and check for leaks.
11. Check and delete any fault codes that are
been completed. See Fault Codes on
page 13-18.
If the fuel feed pump refuses to prime:

The fuel feed pump may not prime because it is
working against fuel remaining in the fuel system. (2)
Perform the following steps:
Figure 6-25
(3)
(2) (1)
Figure 6-26
1. Close the fuel tank cock (Figure 6-26, (1)).
2. Loosen the drain plug (Figure 6-26, (3)) and
drain off any water and dirt collected inside.
NOTICE: If the fuel filter / water separator is
positioned higher than the fuel level in the fuel
tank, water may not drip out when the fuel
filter / water separator drain cock is opened. If
B107676A
this happens, turn the air vent screw on the top
1 – Inlet Pipe of the fuel filter / water separator 2-3 turns
2 – Outlet Pipe counterclockwise. Be sure to tighten the air vent
Figure 6-25 screw after the water has drained out.
1. Detach the inlet pipe (Figure 6-25, (1)) at the

fuel filter. WARNING! Wear eye protection.
The fuel system is under pressure and fuel
could spray out when you remove any fuel
system component.

Repair FUEL SYSTEM
12/05
Figure 6-276SY Engines Replace the Fuel Filter / Water Separator

Figure 6-29
(1)
Figure 6-27 (2)

(3)
Figure 6-29
1. Close the fuel tank cock (Figure 6-29, (1)).
2. Loosen the drain plug (Figure 6-29, (3)) at the
bottom of the fuel filter / water separator and
drain off any water and dirt.
3. Turn the filter container (Figure 6-29, (2))
counterclockwise to remove.
4. Remove the old filter. Lubricate the seal, insert
the new filter into the container and
Figure 6-28
hand-tighten.
3. Clean the outside of the filter and remove it by 5. Turn the filter container clockwise to install.
turning it counterclockwise.
6. Open the fuel tank cock (Figure 6-29, (1)).
4. Install a new Yanmar filter and tighten by hand.
7. After reassembling the fuel filter / water
5. Bleed the fuel system. See Bleed the Fuel separator, vent air from the fuel system. See
System on page 6-17. Bleed the Fuel System on page 6-17.
Replace Return Fuel Line

first.
2. Shut off all valves in the fuel supply system.
3. Open the bleeder valve and drain the fuel
system by loosening the banjo screw on the
back of the fuel manifold. Catch fuel in an
appropriate container.

FUEL SYSTEM Repair
6SY Engines Replacing Plastic Tubing on a Banjo Union

Specifications 1. Remove tubing to be replaced.
Figure 6-31
Minimum Internal
Tubing Diameter
Diameter of Bend
6 mm Union Nut 35 mm (1.38 in.)
12 mm Union Nut 95 mm (3.74 in.)
Replacing Plastic Tubing on a Union

Figure 6-30
Figure 6-31
2. Cut plastic tubing with pipe cutter (OEM Part
No. 587 258 or similar tool) to length shown in
1 – Plastic Tube Figure 6-31:
2 – Union Nut (Figure 6-31, (A)) Length = 106 mm (4.17 in.)
3 – Ferrule
4 – Insert Sleeve (Figure 6-31, (B)) Length = 151 mm (5.94 in.)
5 – Union Figure 6-32
Figure 6-30
1. Remove tubing to be replaced and use as
pattern to cut the new tubing to length.
NOTICE: Avoid sharp bends when installing
plastic tubing. If the tubing is bent into a
diameter smaller than specified, a kink may
develop in the tubing and restrict the fuel flow.
2. Install union nut, ferrule and insert sleeve in end
of tubing.
3. Insert tubing into union until it bottoms.
4. Hold tubing securely in the union and install
union nut. Tighten union nut to specification. Figure 6-32
Specifications 3. Hold plastic tubing tightly with pliers (OEM Part
Tubing Diameter Torque No. 587 956 or similar tool) and install the
union.
6 mm 10 N·m (89 in.-lb)
12 mm 20 N·m (177 in.-lb) 4. Tap the union onto the tubing using a plastic
mallet (Figure 6-32). NOTICE: Do not use a
metal hammer. Damage to the union will result.

Repair FUEL SYSTEM
12/05
8SY Engines Bleed the Fuel System

Figure 6-33
The fuel system needs to be bled under the

following conditions:
• Before starting the engine for the first time.
• After running out of fuel and fuel has been added
to the fuel tank.
• After fuel system maintenance such as changing
the fuel filter and draining the fuel filter / water
separator, or replacing a fuel system component.
(1)
0002713
Figure 6-33
NOTICE: The return line is pre-shaped and must
not be replaced with bulk plastic tubing because of
the risk of wear against other parts. The return line
is pre-shaped and is available as a replacement
part. See parts catalog for correct part number. (2)
Install as shown (Figure 6-33).
3:5829B
Figure 6-34

FUEL SYSTEM Repair
Figure 6-358SY Engines 5. Continue hand pumping until there is

resistance:
• Approximately 20 strokes after replacing the
fuel filter
(1) • Approximately 50 strokes after replacing a fuel
(1) injector
6. Start the engine and check for leaks. NOTICE:
NEVER hold the key in the START position for
longer than 15 seconds or the starter motor will
overheat.
If the engine fails to start after bleeding:

• Open the bleeder valves again and operate the
hand pump until fuel without air bubbles flows out.
(2) • Tighten the bleeder valves. Start the engine and
check for leaks.
0002705A
Figure 6-35
1. Install a transparent plastic hose on each fuel
rail bleeder valve. Place the hoses in an
appropriate container.
2. Open the bleeder valve (Figure 6-34, (1)) or
(Figure 6-35, (1)) and operate the hand pump
(Figure 6-34, (2)) or (Figure 6-35, (2)) until fuel
flows without air bubbles. This may take 130 -
150 pump strokes. WARNING! Place an
approved container under the air bleed port
when you prime the fuel system. Never use
a shop rag to catch the fuel. Wipe up any
spills immediately. ALWAYS close the air
bleed port after you complete priming the
system.
3. Close the bleeder valves and remove the
hoses.
4. Dispose of waste fuel properly.

Section 7
COOLING SYSTEM
Page
Introduction...................................................................................... 7-3
Specifications .................................................................................. 7-4
Pressure Testing Cooling System and Filler Cap...................... 7-7
Testing the Thermostat.............................................................. 7-8
Repair.............................................................................................. 7-8
Drain, Flush and Fill the Engine with Engine Coolant ............... 7-8
Venting the Cooling System - 8SY Engines Only...................... 7-9
Coolant Pump Removal........................................................... 7-10
Install Coolant Pump ............................................................... 7-11
Remove and Install Pulley ....................................................... 7-11
Change the Coolant Pump Seal .............................................. 7-12
Remove and Install Thermostat............................................... 7-14
Remove and Install Fresh Water Charge Air Cooler ............... 7-15
Remove and Install Seawater Charge Air Cooler -
6SY Engines Only ................................................................... 7-18
Seawater Pump ....................................................................... 7-24
Check or Replace the Zinc Anodes ......................................... 7-28

COOLING SYSTEM

Introduction COOLING SYSTEM
12/05
INTRODUCTION
This section of the Service Manual describes the Only use the engine coolant specified. Other
procedures necessary to service the 6SY and 8SY engine coolants may affect warranty coverage,
marine engine cooling systems. cause an internal buildup of rust and scale and / or
See Engine Piping Diagrams on page 3-6 for shorten engine life.
cooling system flow information.
Prevent dirt and debris from contaminating the
engine coolant. Carefully clean the radiator cap and
the surrounding area before you remove the cap.
NEVER mix different types of engine coolants. This

may adversely affect the properties of the engine
coolant.

COOLING SYSTEM Specifications
SPECIFICATIONS
Note: All pressure specifications are with engine at normal operating temperature.
Inspection Item Model Specification Reference Page
Cooling System Test All 0.4 - 0.5 bar See Pressure Testing
Pressure (5.8 - 7.3 psi) Cooling System and
Filler Cap Test Pressure All 0.4 - 0.6 bar Filler Cap on page 7-7
(5.8 - 8.7 psi)
Thermostat Marking Starts Opening Fully Open See Testing the
6SY 75°C 73 - 77°C 87°C (189°F) Thermostat on
(163 - 171°F) page 7-8
8SY 75°C 73 - 77°C 87°C (189°F)

(163 - 171°F)
Repair Specifications
Coolant Recovery Tank Level - Cold Engine 50 mm (2 in.) Below Filler
Coolant Pump Impeller Installation Distance 13.3 - 13.7 mm (0.524 - 0.539 in.)
Volume Including Heat Exchanger and Reserve Tank 6SY 40 L (10.5 gal)
8SY 75 L (20 gal)

Lubricating Oil
Application
Charge Air Cooler Bolt 26 N·m (230 in.-lb) Not Applied See Remove and Install
Upper Manifold Housing 6SY 26 N·m (230 in.-lb) Not Applied Fresh Water Charge Air
Bolt Cooler on page 7-15
8SY 50 N·m (37 ft-lb)
Inlet Pipe V-Clamp M6 Screw 8N·m (71 in.-lb) Not Applied
M8 Screw 20 N·m (177 in.-lb) Not Applied
Heat Exchanger Retaining Nut 50 N·m (37 ft-lb) Not Applied See Remove and Install
the Heat Exchanger on
page 7-20
Seawater Pump Gear Nut 100 N·m (74 ft-lb) Not Applied See Seawater Pump on
page 7-24

Special Service Tools C O O L IN G S Y S T E M
12/05

No. Tools not having part numbers must be obtained locally.

1 Cooling System OEM Part No. 587 048
Tester (For
Pressure-Testing
the Cooling
System and Filler
Cap)
2 Puller (Used for OEM Part No. 587 315

Removing Belt
Pulley)
3 Drift (Used for OEM Part No. 87 664

Removing Belt
Pulley)
4 Puller (For OEM Part No. 98 736

Removing
Coolant Pump
Impeller)
5 Drift For OEM Part No. 87 664

Removing
Coolant Pump
Impeller)
6 Seal Installer (For OEM Part No. 99 117

Installing Seal in
Coolant Pump)

COOLING SYSTEM Measuring instruments

7 Impeller Puller OEM Part No. 98 482
(For Removing
Seawater Pump
Impeller)
Measuring instruments
1 Calipers For measuring outside diameters, depth,
thickness and width
0000836

torque
0000840

Tests and Adjustments COOLING SYSTEM
12/05
TESTS AND ADJUSTMENTS 5. Pump until the pressure is 0.4 - 0.5 bar
(5.8 - 7.3 psi) (Figure 7-1).
Pressure Testing Cooling System 6. If the pressure drops, there is leakage in the
and Filler Cap system. Start by checking all hoses and pipe
connections.
Cooling System
Filler Cap
Use a cooling system tester with connections
Note: Applies to cooling system with pressure
compatible with the Yanmar SY series cooling
cap.
system, such as Leitenberger TVK 138/3 (OEM
Part No. 587 048 or similar tool). Figure 7-2
1. Remove the coolant recovery tank filler cap.

WARNING! NEVER remove the coolant filler
cap if the engine is hot. Steam and hot
engine coolant will escape and seriously
burn you. Allow the engine to cool before
attempting to remove the filler cap.
2. Check that the lugs and sealing flange on the
filler pipe are undamaged and free from
anything that might prevent a good seal.
3. Check that the coolant level is correct. Fill with
coolant as necessary. See Drain, Flush and Fill
the Engine with Engine Coolant on page 7-8.
Figure 7-1
Figure 7-2
1. Connect the cap to the cooling system tester
using the adapter for the cap.
2. Pump up the pressure until the cap opens
(Figure 7-2).
3. The tester needle should stop between
0.4 - 0.6 bar (5.8 - 8.7 psi) for pressure caps
with an opening pressure of 0.5 bar (7.3 psi).
Figure 7-1
4. Install the tester and adapter in place of the
radiator cap.

COOLING SYSTEM Repair
Testing the Thermostat REPAIR

1. The design temperature for the thermostat is
stamped into the thermostat body. Find and Drain, Flush and Fill the Engine with
record this number. Engine Coolant
2. Immerse one thermostat at a time in a Cooling performance drops when coolant is
container of water. Suspend it so that it does contaminated with rust and scale. The coolant must
not come into contact with the walls or bottom be replaced periodically because its properties
of the container. deteriorate over time.
3. Slowly heat the water and monitor the
temperature with a thermometer. Stir the water. 1. Remove the filler cap from the coolant recovery
tank. WARNING! NEVER remove the coolant
4. Check that the thermostat begins to open at the filler cap if the engine is hot. Steam and hot
specified temperature, and that it is fully open at engine coolant will escape and seriously
the temperature given in the specifications. burn you. Allow the engine to cool
If it does not open at the specified temperature, it sufficiently before attempting to remove the
should be replaced. filler cap. NOTICE: Prevent dirt and debris
from contaminating engine coolant. Carefully
Specifications clean the heat exchanger cap and surrounding
Starts area before you remove the cap.
Marking Fully Open
Opening Figure 7-3
75°C 73 - 77°C 87°C (189°F)

(163 - 171°F)
(3)
(2)
(1)
(4)
0004410
Figure 7-3
2. Drain the coolant:
• Open the two drain taps on the two hoses
(Figure 7-3, (4)) fastened in the side cover on
the ride side of the block (Figure 7-3, (1)).
• Open the drain tap located on the lower left side
of the block (Figure 7-3, (2)).
• Remove the two plugs (Figure 7-3, (3)) below
the heat exchanger (if equipped).
3. Close the drain taps and reinstall the heat
exchanger plugs (if equipped).

Repair COOLING SYSTEM
12/05
4. Fold the hoses and attach them to the bracket. Venting the Cooling System - 8SY
Engines Only
Figure 7-4
1
1. Remove the filler cap from the coolant recovery
tank. WARNING! NEVER remove the coolant
filler cap if the engine is hot. Steam and hot
engine coolant will escape and seriously
burn you. Allow the engine to cool
2 sufficiently before attempting to remove the
4 filler cap. NOTICE: Prevent dirt and debris
from contaminating engine coolant. Carefully
clean the heat exchanger cap and surrounding
area before you remove the cap.
3
Figure 7-5
(1)
0002067
Figure 7-4
5. Inspect the cap gasket (Figure 7-4, (2)) and
flange on the filler pipe (Figure 7-4, (4)) for
damage.
6. Check the rubber hose connecting the coolant
recovery tank to the heat exchanger. Be sure
the hose is securely connected and there is no
looseness or damage.
7. Pour coolant mix slowly into the heat exchanger
(Figure 7-4, (3)) to prevent the formation of air
pockets. Fill until the coolant overflows from the
filler port.
8. Install the fill cap and tighten firmly.
9. Remove the coolant recovery tank cap and fill
with coolant mix to approximately 50 mm (2 in.)
below the full line. Replace cap. Never fill to the
full line.
10. 6SY Engines: After filling an empty cooling
system, test-run the engine for about five
minutes and check the engine coolant level
again.
11. 8SY Engines: After filling an empty cooling
system, vent the system. See Venting the
Cooling System - 8SY Engines Only on 0004705
page 7-9.
Figure 7-5
2. Start the engine and loosen the two bleed
screws (Figure 7-5, (1)).

3. When coolant with no air bubbles starts to flow, Figure 7-78SY Engine
tighten the bleed screws. NOTICE: Dispose of
waste properly. (5)
(4)
4. Run the engine until it is hot and the thermostat (3)
(2)
opens.
5. Add more coolant if necessary. NOTICE:
NEVER add cold coolant to a hot engine.
(1) (6)
Serious engine damage may result.
6. Install coolant recovery tank cap.
Coolant Pump Removal

Figure 7-66SY Engine
(8)
(7) (10)
(6) (9)
(5) (8)
(4)
(3)
(2) (7) 0003489
1 – Pulley
(1) 2 – Pump Housing
3 – Shaft with Bearing
4 – Mechanical Seal Assembly
5 – Impeller
6 – Guide Sleeve
0003483
7 – Gasket
1 – Pulley 8 – Front Cover
2 – Pump Housing 9 – Gasket
3 – Gasket 10 – Gasket
4 – Shaft with Bearing
Figure 7-7
5 – Mechanical Seal Assembly
6 – Guide Sleeve 1. Remove the coolant recovery tank filler cap.
7 – Impeller WARNING! NEVER remove the coolant filler
8 – Front Cover cap if the engine is hot. Steam and hot
Figure 7-6 engine coolant will escape and seriously
burn you. Allow the engine to cool before
attempting to remove the filler cap.
2. Drain coolant from engine:
• 6SY: Open the drain cock on the right-hand
side of the engine block, and remove two plugs
from the underside of the heat exchanger.
• 8SY: Remove two plugs from the underside of
the heat exchanger.
3. Remove the belt guard.

12/05
4. Remove the alternator belt. See Replace Remove and Install Pulley
Alternator Belt on page 11-9.
1. Remove coolant pump from engine. See
5. Remove the coolant pump assembly from front Venting the Cooling System - 8SY Engines
cover. Only on page 7-9.
Figure 7-9
Install Coolant Pump

Figure 7-8
(1)
0003484
Figure 7-8
1. The seal on the coolant pump must be
lubricated with paraffin oil before being
installed:
• Spray oil through the holes in the impeller
(Figure 7-20, (1)). Try to aim the oil toward the
Figure 7-9
shaft.
• Rotate the impeller 180°. 2. Remove the pulley using puller (OEM Part No.
587 315 or similar tool) and drift (OEM Part No.
• Spray oil into the other hole.
87 664 or similar tool). NOTICE: Support the
• Rotate the impeller a few turns to ensure that bottom end of the pump shaft when pressing
the oil has coated the entire seal. pulley into place. Failure to do so could result in
2. Ensure that the mating surfaces on the pump the pump shaft position moving, resulting in a
and pump housing are clean. Install the pump coolant leak or seal damage.
and a new gasket. Figure 7-10
3. Install the alternator belt. See Replace

Alternator Belt on page 11-9.
4. Install the belt guard.
5. Fill engine block with coolant. See Drain, Flush
and Fill the Engine with Engine Coolant on
page 7-8.
6. Start the engine and check for coolant leaks.
Check the level of the coolant and fill as
necessary.
Figure 7-10

3. Press the pulley onto the shaft until it is flush

Figure 7-12
with the shaft end face.
Change the Coolant Pump Seal

1. Remove coolant pump from engine. See
Venting the Cooling System - 8SY Engines
Only on page 7-9.
2. Place the pump with pulley on a flat surface.
NOTICE: Support the bottom end of the pump
shaft when pressing pulley into place. Failure to
do so could result in the pump shaft position
moving, resulting in a coolant leak or seal
damage.
Figure 7-11
0003485
Figure 7-12
4. Remove the seal using puller (OEM Part No.
587 516 and OEM Part No. 587 518 or similar
tools). The seal will divide into two parts with
the outer ring remaining in the coolant pump
(Figure 7-12).
Figure 7-13
0003486

3. Remove the impeller using puller (OEM Part 5. Remove the outer ring by heating the area
No. 98 736), two M8 x 65 mm bolts and drift around the seal with a hot air gun to release the
(OEM Part No. 87 664 or similar tools). locking agent. NOTICE: Do not damage the
pump housing sealing surface.
6. Bend up the edge of the outer ring with two
screwdrivers and remove the ring (Figure
7-13).

12/05
7. Apply sealing agent (OEM Part No. 561 200 or

Figure 7-15
similar) to the inside and outside of the sealing

ring (brass sleeve). Make sure that no sealing
agent gets onto other sealing surfaces.
NOTICE: Use sealing agent sparingly. Excess
sealing agent can cause the two mating seal
surfaces to become glued together. Seals
which have sealing agent pre-applied should
not have more sealing agent applied to them.
Figure 7-14
0003487
Figure 7-15
9. NOTICE: If you have the old-style OEM Part No.
99 117, it must be modified to install the new
seal. If the seal is installed with a tool that has
not been modified, the seal will break which will
result in leakage. Modify the tool to the
dimensions shown in Figure 7-15.
Figure 7-16
(1)
Figure 7-14
8. NOTICE: It is very important that tool OEM Part
No. 99 117 is used. It is designed to correctly
preload the spring which holds the seal. Press
in the new seal using OEM Part No. 99 117 until
the edge of the brass sleeve abuts against the
pump housing. Keep it under pressure for about
10 seconds (Figure 7-14).
0003488
Figure 7-16
10. Measure the seal recess diameter (Figure
7-16, (1)). If it measures 30.7 mm, it must be
enlarged to 33.0 mm using a lathe. NOTICE: If
the impeller seal recess diameter (Figure
7-16, (1)) in the housing is 30.7 mm, it must be
modified to install a new seal. Otherwise the
seal will be damaged which will result in
leakage.

11. Support the bottom end of the impeller shaft to 6SY Thermostat Removal
prevent movement of the impeller shaft.
NOTICE: Failure to support the bottom end of Figure 7-186SY Engine
the pump shaft could result in the pump shaft
(1)
position moving, resulting in a coolant leak or (2)
(3)
seal damage. (4)
Figure 7-17
(5)
(6)
(7)
0003490
1 – Connection Pipe
2 – O-Ring
3 – Gasket
4 – Thermostat Housing
5 – Seal
6 – Thermostat
7 – Thermostat Housing Cover
Figure 7-18
Figure 7-17
1. Remove the clamp ring and water lines
12. Press on the impeller using drift (OEM Part No. between thermostat housing and charge air
99 117) until the distance between the pump cooler.
housing gasket surface and the impeller shaft 2. Remove the tube from the front cover to the
surface (Figure 7-17, (A)) is 13.3 - 13.7 mm heat exchanger.
(0.524 - 0.539 in.).
3. Remove bolts from the connection housing at
Remove and Install Thermostat the back of the front cover and remove it along
with the charge air thermostat housing, bypass
Drain a sufficient amount of coolant from the pipe and outlet pipe from the heat exchanger.
system to get coolant level below thermostat.
CAUTION! Wear eye protection and rubber 4. Remove the thermostat housing cover along
gloves when you handle Long Life engine with the inlet pipe to the heat exchanger.
coolant. If contact with the eyes or skin should 5. Remove the thermostat.
occur, flush eyes and wash immediately with 6. Test thermostat as required. See Testing the
clean water. Thermostat on page 7-8.
• 6SY: Open the drain cock on the right side of the
engine block, and removing two plugs from the
underside of the heat exchanger.
• 8SY: Remove two plugs from the underside of the
heat exchanger.

12/05
Thermostat Removal - 8SY Remove and Install Fresh Water

Figure 7-198SY Engine Charge Air Cooler
Figure 7-20
(1)
(1) (2)
(7)
(6) (3)
(2) (4)
(5)
0003491
1 – Connection Pipe
2 – Thermostat Housing Cover
Figure 7-19
1 – Upper Intake Housing
1. Remove the hose from the thermostat housing 2 – Seal
cover. 3 – O-Ring
4 – Coolant Pipe
2. Remove the thermostat housing cover and 5 – Lower Intake Manifold
remove the thermostat. 6 – Gasket
3. Test thermostat as required. See Testing the 7 – Intake Air Cooler
Thermostat on page 7-8. Figure 7-20
Thermostat Installation - All Engines Note: 8 SY engine shown.
1. Clean the thermostat housing and check that 1. Drain coolant from the engine:
nothing can obstruct the function of the
• 6SY: Open the drain cock on the right side of
thermostat(s).
the engine block, and removing two plugs from
2. Place the thermostat(s) in the housing. Install the underside of the heat exchanger.
new gaskets and install the thermostat housing.
• 8SY: Remove two plugs from the underside of
3. Install all pipes and connections that were the heat exchanger.
removed.
2. 8SY: Remove the connection pipe between
4. Fill the system with coolant. See Drain, Flush upper intake manifold housings.
3. Disconnect the pipe between intake manifold
page 7-8.
and turbocharger.
4. 6SY: Remove the charge air thermostat
housing from intake manifold. Cap the fittings to
necessary.
prevent coolant spillage.

5. 8SY: Disconnect inlet and outlet water lines

from charge air cooler fittings. Cap the fittings to
prevent coolant spillage.
6. Remove the upper intake manifold housing.
NOTICE: Take care to ensure that no coolant
spills from the element into the intake manifold.
7. Remove the charge air cooler assembly from
each intake manifold.
8. Clean the element using paraffin-based engine
detergent only. NOTICE: NEVER use caustic
soda to clean the components.
9. Clean and degrease the sealing surfaces on the
upper and lower intake manifold housings.
10. Install charge air cooler(s) and a new gasket.
Tighten bolts to 26 N·m (230 in.-lb).
11. Install upper intake manifold(s). Tighten bolts
to:
6SY: 26 N·m (230 in.-lb)
8SY: 50 N·m (37 ft-lb)
12. 8SY: Install connection pipe between intake
manifolds.
13. 8SY: Connect coolant hoses to charge air
coolers.
14. 6SY: Install thermostat housing to front of
intake manifold with new gasket and O-rings.
15. Install and secure all remaining air inlet pipes
and hoses. Tighten V-clamps to:
• M6 Screw: 8 N·m (71 in.-lb)
• M8 Screw: 20 N·m (177 in.-lb)
16. Fill the system with coolant. See Drain, Flush
page 7-8.
necessary.

12/05

Remove and Install Seawater Charge Air Cooler - 6SY Engines Only
Figure 7-21
(1)
(2)
(21)
(3)
(4)
(22)
(19) (20)
(23) (19)
(6) (5)
(10)
(11) (9)
(8)
(7)
(10)
(12)
(12)
(5) (16) (13)
(17) (14)
(10)
(18) (15)
0004667_m1
Figure 7-21

12/05
1 – To Intake Manifold
2 – Hose Clamp
3 – Hose
4 – Hose Clamp
5 – Screw (8 used)
6 – Cover
7 – Plug
8 – Sealing Ring
9 – Zinc Anode
10 – O-Ring
11 – Seawater Charge Air Cooler Core
12 – Flange Screw (M10 x 50 mm) (3 used)
13 – Flange Screw (M10 x 50 mm)
15 – Bracket
16 – O-Ring
17 – Flange
18 – Cover
19 – O-Ring
21 – Charge Air Pipe
23 – Holder

Remove and Install the Heat Exchanger

6SY Engines
Figure 7-22
(1)
(2)
(3)
(8)
(4) (5)
(9)
(10) (6)
(5)
(7)
(11)
(21)
(22)
(14) (20)
(12)
(15)
(19)
(12) (23)
(18) (13)
(12) (14)
(14) (18)
(15)
(17) (15)
(16) (12)
(24)
(25) (13)
(26)
1 – Screw 13 – Seal
2 – Nameplate 14 – Bolt
3 – Filler Cap 15 – Seal
4 – Heat Exchanger Housing 16 – Anode (3 used)
5 – O-Ring 17 – Front Cover
6 – Return Pipe to Coolant Pump 18 – O-Ring
7 – Bolt 19 – Drain Plug
9 – Plug 21 – Flange Nut
10 – Gasket 22 – Bolt
11 – Outlet Pipe from Engine 23 – Rear Cover
12 – Bolt 24 – Gasket
25 – Cooler Core
26 – O-Ring
Figure 7-22

12/05
1. Drain coolant from the engine. 16. Fill the system with coolant. See Drain, Flush
2. Drain the seawater circuit by removing the and Fill the Engine with Engine Coolant on
cover from the seawater pump and the page 7-8.
connections from the heat exchanger outlet. 17. Start the engine and check for coolant leaks.
3. Disconnect the coolant pipes from the charge Check the level of the coolant and fill as
air cooler. Disconnect the pipe between the necessary.
front cover and the heat exchanger.
4. Remove the connection housing at the coolant
pump inlet along with the return pipe from the
heat exchanger.
5. Remove the thermostat housing cover and the
outlet pipe to the heat exchanger.
6. Remove the seawater inlet flange from the heat
exchanger.
7. Remove the vent pipe from the coolant recovery
tank.
8. Remove the flange nuts and lift off the complete
heat exchanger assembly.
9. Remove the rear cover and pull out the cooler
element.
10. Use paraffin-based engine detergent to clean
the cooler element. NOTICE: NEVER use
caustic soda to clean the components.
11. Any internal deposits in the tubes can be
removed using a round rod.
Note: Always install new gaskets and O-rings.
12. Lubricate and install a new O-ring (Figure
7-22, (26)) inside the housing and install the
cooler core. NOTICE: Make sure all O-rings are
correctly installed in their grooves. Failure to do
so will result in leaks causing oil and coolant to
mix.
13. Install the front and rear covers using new
O-rings and gaskets.
14. Install the heat exchanger assembly on the
engine. Tighten the flange nuts to 50 N·m
(37 ft-lb).
15. Install the coolant inlet and outlet pipes,
thermostat housing cover, connection housing,
charge air cooler coolant pipes and thermostat
housing.

8SY Engines
Figure 7-23
(15) (14)
(1) (16)
(2)
(3)
(2)
(7) (2)
(4)
(8)
(2)
(5)
(6)
(9)
(7)
(13)
(10) (2)
(2)
(11)
(2)
(12)
(2)
(3)
0004668
Figure 7-23

12/05
1 – Heat Exchanger Housing, Main Section 10 – Cover

2 – O-Ring (8 used) 11 – Heat Exchanger Core
3 – Flange (2 used) 12 – Housing
4 – Cover 13 – Flange Nut (M8) (4 used)
5 – Sealing Ring 14 – Flange
6 – Plug 15 – O-Ring
7 – Screw (M8 x 35 mm) (4 used) 16 – Screw (M8 x 30 mm) (4 used)
8 – Housing
9 – Heat Exchanger Core

1. Drain coolant from the engine. Seawater Pump

2. Drain the seawater circuit by removing the
cover from the seawater pump and the Replace the Impeller
connections from the heat exchanger outlet. 1. Drain the seawater circuit by removing the
3. Disconnect all connections to the heat cover from the seawater pump.
exchanger and to the reverse gear oil cooler, if 2. 8SY: Detach the outlet pipe.
installed.
3. Remove the rubber washer from the center of
4. Remove the heat exchanger. the impeller.
5. Remove the rear cover and pull out the charge
air cooling element.
6. Remove the charge air section housing,
intermediate section housing and front cover.
7. Remove the main section element. It may be
necessary to tap the element carefully in order
to loosen it.
8. Use paraffin-based engine detergent to clean
the elements. NOTICE: NEVER use caustic
soda to clean the components.
9. Any internal deposits in the tubes can be
removed using a round rod.
Figure 7-24
Note: Always install new gaskets and O-rings.
10. Lubricate and install the O-rings on the
elements and assemble in reverse order.
NOTICE: Make sure all O-rings are correctly
installed in their grooves. Failure to do so will
result in leaks causing oil and coolant to mix.
11. Fill the system with coolant. See Drain, Flush
page 7-8.
necessary.
Figure 7-25
4. Extract the impeller using puller (OEM Part No.
98 482 or similar tool).

12/05
Note: When installing the new impeller, bend

Figure 7-28
(4)
the vanes in the same direction as on the
(3)
old one. (5)
(2) (1) (6)
5. Install the new impeller and the rubber washer. (7)
Attach the cover using a new gasket. (1)
(8)
(9)
Remove and Disassemble Seawater Pump
1. Remove the inlet and outlet connections from
the pump.
2. Remove the securing screws from the timing (10)
gear cover and remove the pump. (11)
Figure 7-26
(12) (13)
(14)
(15)
0003494
1 – Retaining Ring
2 – Ball Bearing
3 – Retaining Ring
4 – Shaft
5 – Lip Seal
Figure 7-26 6 – Deflector Ring
7 – Mechanical Seal
3. Clamp the pump housing in a soft-jawed vise. 8 – Retaining Ring
Remove the nut and remove the gear using a 9 – Pump Housing
universal puller (Figure 7-26). 10 – Pin
Figure 7-27
11 – Comb
12 – Impeller
13 – Wear Washer
14 – Gasket
15 – Impeller Cover
Figure 7-28
6. Remove the comb and wear washer.
Figure 7-27
4. Remove the impeller cover and gasket.
5. Extract the impeller using puller (OEM Part No.
98 482 or similar tool) (Figure 7-27).

Figure 7-31
Figure 7-29 10. Remove the retaining rings from both sides of
the bearing and place the shaft and bearing in a
7. Remove the retaining ring from the housing press between parallel pieces. Press the shaft
(Figure 7-29). out of the bearing (Figure 7-31).
Figure 7-30
Inspect the Seawater Pump

Clean all parts except the mechanical seal
components and check:
• That the splines on the shaft are not damaged.
• That the bearing can be easily rotated and is not
damaged, and that it has not rotated on the shaft
or in the housing.
• That the comb is not too worn or defective.
Replace parts which are defective or worn.
Figure 7-30
8. Remove the retaining ring from the shaft on the
impeller side of the bearing (Figure 7-30). Tap
the shaft and bearing out of the housing.
9. Remove the ceramic ring and rubber sleeve
from the seat on the water side. Remove the
deflector ring. Tap out the lip seal.

12/05
Assemble the Seawater Pump

Figure 7-34
Figure 7-32
Figure 7-34
Figure 7-32 3. Tap the shaft and bearing into the housing until
the bearing is against the shoulder in the
1. Place the bearing on parallel pieces in a press housing. Install the retaining ring (Figure 7-34).
so that the inner race is also supported. Press
4. Turn the housing in the vise. Push the deflector
the shaft to the correct position (Figure 7-32)
ring as far onto the shaft as possible.
and install the retaining rings. Figure 7-35
Figure 7-33
Figure 7-35
5. Install a new mechanical seal onto the shaft as
Figure 7-33 follows:
• Press the rubber sleeve into the seat in the
2. Mount the pump housing in a soft-jawed vise. housing (Figure 7-35).
Use a drift or tube with an outside diameter of
60 mm and tap a new seal into the housing. • Apply a little oil around the outside of the
Install the seal so that the lip faces out (Figure ceramic ring and press it into the rubber sleeve
7-33). with the flat surface facing out.
• Push the rest of the mechanical seal
components onto the shaft with the ceramic
ring installed first.
• Press the seal assembly in past the retaining
ring groove and install a new retaining ring.

6. Install a new wear washer. Install a new copper 8. Lightly tap the gear onto the end of the shaft.
washer onto the comb retaining screw and Tighten the nut to 100 N·m (74 ft-lb).
attach the comb. 9. Make sure that the overflow holes in the pump
7. Install the impeller and fasten the cover with a housing are open.
new gasket.
Check or Replace the Zinc Anodes

( 2)
(3)
(4)
(1)
0004395_s1
Figure 7-36

12/05
0004414_s1
Figure 7-37
1. Drain the seawater cooling circuit and check the

anodes.
2. Scrape off all loose material on the anodes.
3. A new anode is 63 mm (2.50 in.) long with a
diameter of 17 mm (11/16 in.). Replace an
anode if less than half of the anode remains.
NOTICE: NEVER use thread sealer or thread
sealing tape when installing zinc anodes.
Anodes must make good metal-to-metal
contact to perform properly.
NOTICE: If operation is continued with an anode
less than half of the new anode length, corrosion
of the seawater coolant system will occur and
water leakage or parts breakage will result.
Note: If the anodes are extremely corroded,
check them more frequently.


Section 8
LUBRICATION
Page
Introduction...................................................................................... 8-3
Specifications .................................................................................. 8-3
Check the Engine Oil Pressure ................................................. 8-5
Repair.............................................................................................. 8-6
Remove and Install the Oil Cooler............................................. 8-6
Remove and Install Oil Cleaning Components.......................... 8-9
Replace the Engine Oil Filter - 8SY......................................... 8-11
Clean the Centrifugal Engine Oil Cleaner................................ 8-11
Oil Pump.................................................................................. 8-14

LUBRICATION

Introduction LUBRICATION
12/05
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 6SY and 8SY
lubrication systems.
SPECIFICATIONS
Note: All pressure specifications are with engine at normal operating temperature.
Inspection Item Model Test RPM Specification
Oil Pressure 6SY Idle 1.6 bar (23 psi)
1000 rpm 2.5 bar (36 psi)
2000 rpm 4.5 - 6.0 bar (65 - 87 psi)
8SY Idle 1.4 bar (20 psi)
1000 rpm 3.0 bar (43 psi)
2000 rpm 3.5 - 5.5 bar (51 - 80 psi)
Oil Pressure Relief Valve Spring Free Length 6SY - 61.4 mm (2.417 in.)
Maximum Thickness of Deposits on Walls of Centrifugal Oil Cleaner Bowl 20 mm (0.75 in.)

Lubricating Oil
Application
Oil Cooler-to-Cover Bolt 26 N·m (230 in.-lb) Not Applied See Remove and Install
the Oil Cooler on
page 8-6
Oil Cleaner Rotor Shaft 34 N·m (25 ft-lb) See Footnote* See Clean the
Rotor Bowl Nut Hand-tighten Not Applied Centrifugal Engine Oil
Cleaner on page 8-11
Centrifugal Oil Cleaner Cover Lock Nut 15 N·m (133 in.-lb) Not Applied
Oil Filter Housing Cover 8SY Engine 25 N·m (221 in.-lb) Not Applied See Replace the Engine
Oil Filter - 8SY on
page 8-11
Oil Sump Bolt 30 N·m (22 ft-lb) Not Applied See Installation of Oil
Oil Pump Mounting Bolt 26 N·m (230 in.-lb) Applied Pump on page 8-15
Oil Sump Drain Plug 80 N·m (59 ft-lb) Not Applied

* Apply medium-strength thread lock and sealer to threads.

LUBRICATION Special Service Tools

No. Tool Name Part Number Illustration

1 Rotor Shaft OEM Part No. 98 421
Socket (For
Removing and
Installing
Centrifugal Oil
Cleaner Rotor
Shaft)
0002383
2 Lifting Eyes OEM Part No. 99 398

(Used to Lift
Engine)
Measuring Instruments
torque
0000840

Tests and Adjustments LUBRICATION
12/05
TESTS AND ADJUSTMENTS Figure 8-2Sensor Location - 8SY
Check the Engine Oil Pressure

Note: The oil pressure relief valve is not a
safety valve.
Perform an engine oil pressure check if there is any
indication of low oil pressure.
1. Start the engine and allow it to warm to normal
operating temperature.
2. Stop the engine. WARNING! ALWAYS keep
your hands and other body parts away from
hot engine surfaces such as the muffler,
exhaust pipe, turbocharger (if equipped)
and engine block during operation and Figure 8-2
shortly after you shut the engine down.
These surfaces are extremely hot while the 3. Remove the oil pressure sensor.
engine is operating and could cause burns. 4. Install a mechanical oil pressure gauge in the
oil pressure sensor port.
Figure 8-1Sensor Location - 6SY
5. Start the engine and read the pressure gauge:
• If the mechanical oil pressure test gauge
indicates good oil pressure, replace the faulty
oil pressure sensor or faulty oil pressure
gauge.
• If the mechanical oil pressure test gauge
indicates low oil pressure, troubleshoot the
lubrication system to locate the cause of the
low oil pressure. See Low Oil Pressure on
page 13-6. Repair as necessary.
Inspection Item Test RPM Specification
Engine Oil 6SY Idle 1.6 bar (23 psi)
Pressure 1000 rpm 2.5 bar (36 psi)
2000 rpm 4.5 - 6.0 bar
(65 - 87 psi)
8SY Idle 1.4 bar (20 psi)
1000 rpm 3.0 bar (43 psi)
2000 rpm 3.5 - 5.5 bar
(51 - 80 psi)
Figure 8-1

LUBRICATION Repair
REPAIR
Remove and Install the Oil Cooler
Figure 8-4
6SY Engines
Figure 8-3
(1)
(6)
(5)
(2) (9)
(3)
(10) Figure 8-4
(4)
4. Remove the side cover and oil cooler from the
(12) cylinder block.
(7) (11) Figure 8-5
(14) (13)
(8) (15)
0002370
1 – Gasket
2 – Flange Bolt
3 – O-Ring
4 – O-Ring
5 – Oil Cooler
6 – Oil Cooler Cover
7 – Flange Bolt
8 – Core Plug
9 – Gasket
10 – Cover
0002372
11 – Bolt
12 – Piston Figure 8-5
13 – Spring
14 – Gasket 5. Remove four bolts securing the oil cooler to the
15 – Plug side cover.
6. Remove the oil cooler.
Figure 8-3
1. Drain engine coolant into a suitable container.
2. Disconnect turbocharger lube line.
3. Remove the oil filter.

Repair LUBRICATION
12/05
8SY Engines
Figure 8-6
Figure 8-7
(3)
(2)
(1)
(4)
(7)
(5)
Figure 8-6 (6)
7. Install four new O-rings.

8. Arrach the oil cooler to the side cover. Tighten (8)
bolts to 26 N·m (230 in.-lb). 0003477
9. Install the oil cooler assembly and new gasket 1 – Flange Bolt
to the cylinder block. 2 – Oil Cooler
3 – Centrifugal Oil Cleaner Assembly
10. Fill the engine with coolant. 4 – Flange Bolt
5 – O-Ring
6 – O-Ring
7 – Oil Cooler Cover
8 – Gasket
Figure 8-7
1. Drain engine coolant into a suitable container.
2. Remove catwalk.
3. Remove pipe between charge air coolers.
4. Remove connection pipe to the closed
crankcase ventilation.
5. Remove centrifugal oil cleaner assembly.
NOTICE: Lift oil cooler and cover assembly
straight up without tipping to prevent oil from
dripping into the cooling system.
6. Remove the oil cooler cover and oil cooler
assembly from the cylinder block.

LUBRICATION Repair
15. Connect the closed crankcase ventilation pipe.

Figure 8-8
16. Fill the engine with coolant.
0002372
Figure 8-8
7. Remove four bolts securing the oil cooler to the
side cover (Figure 8-8).
8. Remove the oil cooler.
Figure 8-9
0002373
Figure 8-9
9. Install two new O-rings on each end of housing.
10. Attach the oil cooler to the cover. Tighten bolts
to 26 N·m (230 in.-lb).
11. Install the oil cooler and cover assembly and
new gasket to the cylinder block.
12. Clean and install the centrifugal oil cleaner. See
Clean the Centrifugal Engine Oil Cleaner on
page 8-11.
13. Install pipe between charge air coolers.
14. Install catwalk.

Repair LUBRICATION
12/05
Remove and Install Oil Cleaning Components

Figure 8-106SY Engines 1 – Filter Head
2 – Gasket
3 – Seal
4 – Straight Union
5 – Gasket
6 – Flange Bolt
7 – Gasket
8 – Plug
9 – Union
(2) (6) (16)
(15) 10 – Overflow Valve
(7) (12)
(8) (17) 11 – Spin-on Oil Filter
(3) (18) 12 – O-Ring
(1) 13 – Strainer
(5) (13)
(9) (20) 14 – Centrifugal Filter Rotor
(4)
(21) 15 – O-Ring
(14) (19) 16 – Locknut
(11) 17 – Lifting Eye
(22)
(10) (33)
18 – Centrifugal Oil Cleaner Cover
19 – O-Ring
(24) 20 – Snap Ring
(25) (26) 21 – Nut
22 – Centrifugal Rotor Bowl
(23) (29)
(28)
23 – Gasket
(31) 24 – Shaft
(30) 25 – Washer
(27) 26 – Plug
(32) 27 – Centrifugal Oil Cleaner Housing
0002374
28 – Gasket
29 – Plug
Figure 8-10 30 – Piston
31 – Spring
32 – Flange Bolt
33 – Nozzle

LUBRICATION Repair
Figure 8-118SY Engines 1 – Filter Cover

2 – O-Ring
(7) 3 – Filter Element
(1) (8) 4 – Tube
5 – Filter Housing
(9) 6 – Gasket
(2) 7 – Locknut
(10) 8 – O-Ring
9 – Centrifugal Oil Cleaner Cover
(11) 10 – Snap Ring
(12) 11 – O-Ring
(3) 12 – Nut
13 – Centrifugal Rotor Bowl
(13) 14 – O-Ring
15 – Nozzle
(14) 16 – Strainer
17 – Centrifugal Filter Rotor
18 – Shaft
(15)
(4) 19 – Washer
20 – Centrifugal Oil Cleaner Housing
(16)
21 – Gasket
(17)
(18)
(19)
(5) (20)
(6)
(21)
0003479
Figure 8-11

Repair LUBRICATION
12/05
Replace the Engine Oil Filter - 8SY 7. Install the filter cover and filter. Tighten to
25 N·m (221 in.-lb).
NOTICE: The centrifugal oil cleaner must be
cleaned when replacing the engine oil filter. 8. Start the engine and inspect the filter housing
for leaks.
Figure 8-12
Clean the Centrifugal Engine Oil

Cleaner
During routine cleaning of the oil cleaner, a small
amount of dirt deposits will accumulate in the rotor
bowl.
If little or no deposits have accumulated, the rotor is
not spinning. The cause must be immediately
investigated.
If dirt deposits exceed 20 mm (0.75 in.) when the
filter is cleaned at the recommended intervals, the
rotor bowl should be cleaned more often.
Figure 8-13
Figure 8-12
NOTICE: Do not use an adjustable wrench or other
open-end tool as there is a risk of damaging the
filter cover.
1. Remove the filter cover using a 6-point socket
or box-end wrench.
2. Lift out the filter housing cover with filter
element attached. The filter housing will drain
automatically once the filter has been removed. Figure 8-13
3. Remove the old filter from the cover by carefully
bending it to one side. 1. Remove the outer cover (Figure 8-13).
4. Make sure all oil has drained from the filter 2. Lift out the rotor bowl and rotor as an assembly.
housing. Wipe the oil filter housing and cover Wipe off the outside of the rotor bowl.
clean.
5. Install a new O-ring on the cover. Lubricate the
O-ring with clean engine oil.
6. Press a new filter element onto the snap
fastener in the cover.

LUBRICATION Repair
• If the rotor nut is difficult to loosen, clamp the

Figure 8-14
nut in a vise and turn the rotor one and a half

turns counterclockwise by hand, or use an M20
bolt as shown in Figure 8-15 and Figure 8-16.
NOTICE: NEVER clamp the rotor in a vise.
NEVER strike the rotor bowl. Doing so may
cause damage resulting in imbalance.
4. Hold the rotor bowl and tap on the rotor nut with
0002376
your hand or a plastic hammer to loosen the
rotor from the bowl.
3. Loosen the rotor nut as follows to prevent

damaging the bearing (Figure 8-14).
• 6SY: Loosen nut approximately one and a half
turns.
• 8SY: Loosen nut approximately three turns.
Figure 8-15
Figure 8-17
5. Remove the nut and rotor bowl from the rotor
(Figure 8-17).
6. Remove the strainer located on the rotor. If the
Figure 8-15 strainer is stuck, pry carefully at the bottom
Figure 8-16
between the rotor and the strainer (Figure
8-17).
Figure 8-18
0002380
Figure 8-18
Figure 8-16
7. Scrape away the deposits inside the bowl with a
knife (Figure 8-18).

Repair LUBRICATION
12/05
8. Wash the parts using an appropriate cleaning • Apply locking compound (OEM Part No.
solvent. 561 200 or similar tool) to the threads of the
9. Inspect the two nozzles on the rotor. Make sure rotor shaft.
they are not blocked or damaged. Replace any • Install the rotor shaft and washer. Tighten
damaged nozzles. using socket (OEM Part No. 98 421 or similar
10. Inspect the bearings for damage or roughness. tool) to 34 N·m (25 ft-lb) (Figure 8-20).
Figure 8-19
Note: It may be necessary to modify socket
OEM Part No. 98 421 as follows:
• Drill out the threads of an M20 nut so that it fits
on the drive end of the socket.
• Weld the nut onto the socket. The socket will fit
the old centrifugal oil cleaner after
modification.
Figure 8-21
0002381
Figure 8-19
11. Install a new O-ring in the rotor bowl.
12. Assemble the parts and hand-tighten the rotor
bowl nut (Figure 8-19). Figure 8-21
Figure 8-20
Note: Note: 8SY components shown. 6SY is

similar.
14. Install the rotor and spin the rotor by hand to
make sure it rotates freely (Figure 8-21).
Figure 8-22
(1)
0002383
Figure 8-20
13. Make sure the rotor shaft is tight in the housing.
If the shaft is loose:
• Remove the rotor shaft and clean the threads in Figure 8-22
the housing and on the shaft using a suitable
solvent. 15. Install a new O-ring on the housing cover lock
nut. Install the washer and locknut (Figure
8-22, (1)). Tighten locknut to 15 N·m
(133 in.-lb).

LUBRICATION Repair
Oil Pump
The oil pump contains no serviceable parts. If the oil pump is damaged or leaks, it must be replaced as an
assembly.
(4) (1)
(2) (3)
(2)
(3)
(3)
(1)
(3)
(5)
(4)
(5) 0003478
1 – Oil Pump
2 – Gasket
(6)
3 – Seal
4 – Pipe
(7) 5 – Oil Pick-Up and Strainer
0002386
Figure 8-24
1 – Oil Pump
2 – Gasket
3 – Seal (2 used)
4 – Pipe
5 – Oil Pick-Up
6 – Strainer
7 – Ring
Figure 8-23

Repair LUBRICATION
12/05
Removal of Oil Pump Installation of Oil Pump

1. Drain oil from oil sump. 1. Install oil pump assembly using a new O-ring
2. Remove debris from the magnet. Install and between oil pump and cylinder block. Tighten
tighten oil plug to 80 N·m (59 ft-lb). bolts to 26 N·m (230 in.-lb).
3. Remove oil sump. 2. Install suction pipe and strainer using new
O-rings.
4. 8SY Engine: Support engine using lifting eyes
(OEM Part No. 99 318 or similar tool) and a 3. 8SY Engine: Install flywheel housing and
suitable hoist. DANGER! ALWAYS use lifting flywheel. See Install the Flywheel Housing on
equipment with sufficient capacity to lift the page 5-53.
marine engine. Additional equipment is 4. Install oil sump. Tighten bolts to 30 N·m
necessary to lift the marine engine and (22 ft-lb).
marine gear together. 5. Fill crankcase to proper level with new engine
5. 8SY Engine: Remove the flywheel housing. oil.
See Remove the Flywheel Housing on
page 5-53.
6. Remove oil strainer assembly and suction pipe.
7. Remove oil pump.

LUBRICATION Repair

Section 9
TURBOCHARGER
Page
Introduction...................................................................................... 9-3
General Information......................................................................... 9-3
Oil Leaks.................................................................................... 9-3
Foreign Bodies .......................................................................... 9-3
Air and Exhaust Leaks............................................................... 9-3
Oil Filter ..................................................................................... 9-3
Cleaning the Compressor Wheel............................................... 9-3
Specifications .................................................................................. 9-4
Component Location ....................................................................... 9-6
6SY Engines.............................................................................. 9-6
8SY Engines.............................................................................. 9-7
Measuring Charge Pressure...................................................... 9-8
Repair.............................................................................................. 9-8
If the Turbocharger Does Not Operate: ..................................... 9-8
Remove Turbocharger............................................................... 9-9
Inspect the Turbocharger ........................................................ 9-10
Measure the Radial and Axial Clearance ................................ 9-10
Install the Turbocharger........................................................... 9-12

TURBOCHARGER

Introduction TURBOCHARGER
12/05
INTRODUCTION Air and Exhaust Leaks

This section of the Service Manual describes the Even small leaks in the line between the air filter
disassembly, inspection, and reassembly of and the turbocharger will cause dirt to be deposited
turbochargers used on 6SY and 8SY engines. on the compressor wheel. The charge pressure will
be reduced, resulting in increased exhaust
temperature and smoke, which will reduce the
service life of the engine.
GENERAL INFORMATION
NOTICE: Observe strict cleanliness at all times Leaks in the exhaust line between the cylinder
when working on the turbocharger. Never leave head and the turbocharger will also result in loss of
connections for oil inlets or outlets unprotected. charging pressure.
Foreign bodies in the bearing housing will lead to
Oil Filter
turbocharger breakdown.
The turbocharger rotates at high speed, sometimes
Oil Leaks above 100,000 rpm.
A blocked air filter creates excess vacuum in the air The turbocharger relies on the engine lubrication
inlet line. There is then a risk of oil mist being drawn system for clean oil. It is vital that scheduled oil and
from the bearing housing. filter changes be performed and the centrifugal oil
If the sealing ring on the turbine side is worn, the cleaner be cleaned to provide maximum
exhaust gases will be blue when idling. turbocharger life. If the oil filter becomes plugged,
oil will pass through a bypass valve without being
If the oil outlet pipe from the turbocharger is filtered, resulting in shortened turbocharger and
damaged, there is risk of oil leaking out. engine life. Always use original Yanmar oil filters to
ensure maximum turbocharger and engine service
Foreign Bodies life.
Foreign bodies in the turbine or compressor, even
as small as a grain of sand or metal shavings, will
Cleaning the Compressor Wheel
ruin the vanes. This will lead to imbalance and 1. Remove the compressor cover. NOTICE: The
bearing wear. Engine power will drop. compressor wheel must not be removed from
the shaft. Imbalance may occur when it is
NOTICE: Never attempt to straighten a damaged reassembled.
vane. It may break off when running and the
turbocharger may stop operating completely, 2. Clean the compressor wheel with white spirit
causing serious damage to the engine. and a brush.
3. Install the compressor cover and measure the
charging pressure again.

TURBOCHARGER Specifications
SPECIFICATIONS
Inspection Item Limit Reference Page
Turbocharger Boost 6SY Minimum - * Maximum - * See Measuring Charge
Pressure 8SY Minimum - * Maximum - * Pressure on page 9-8
Turbocharger Shaft 6SY 0.198 - 0.564 mm See Measure the

Radial Clearance (0.0078 - 0.0222 in.) Radial and Axial
8SY 0.611 mm Clearance on
(0.0240 in.) page 9-10
Turbocharger Shaft Axial 6SY 0.025 - 0.106 mm

Clearance (0.001 - 0.004 in.)
8SY 0.102 mm
(0.004 in.)

Lubricant Application
Component Torque (Thread Portion and Reference Page
Seat Surface)
Turbocharger-to-Exhaust 6SY 50 N·m (37 ft-lb) High-Temperature See Install the
Manifold Bolt 8SY 63 N·m (46 ft-lb) Grease Turbocharger on
page 9-12
Turbocharger-to-Exhaust Pipe Bolt 24 N·m (212 in.-lb) Not Applied
Turbocharger-to-Intake M6 Bolt 8 N·m (71 in.-lb) Not Applied
Pipe V-Clamp M8 Bolt 20 N·m (177 in.-lb) Not Applied

Special Service Tools TURBOCHARGER
12/05


1 Dial Indicator Measure shaft end play
0000831
2 Dial Indicator Measure shaft side play
0000832
3 Magnetic Stand For holding the dial indicator when measuring
0000833

torque
0000840

TURBOCHARGER Component Location
COMPONENT LOCATION
6SY Engines
Figure 9-1
(3)
(2) (4)
(1)
(5)
(12)
(6)
(11)
(10)
(7)
(9)
(8)
0003523
1 – Oil Supply Line 7 – Engine Oil Filter

2 – Gasket 8 – Centrifugal Oil Cleaner
3 – Turbocharger 9 – Oil Return Line
5 – Coolant Return Line 11 – Coolant Supply Line
6 – Heat Exchanger Assembly 12 – Gasket
Figure 9-1

Component Location TURBOCHARGER
12/05
8SY Engines
Figure 9-2
(3)
(2)
(1)
(4)
(5) (3)
(2)
(1) (4)
0003524 9/19 (5)

(10)
(7)
(6) (8)
(6)
(9)
(10)
(9)
0003524
1 – Gasket 6 – O-Ring
2 – Oil Supply Line 7 – O-Ring
3 – Coolant Return Line 8 – Gasket
4 – O-Ring 9 – Coolant Supply Line
5 – Turbocharger 10 – Oil Return Line
Figure 9-2

TURBOCHARGER Tests and Adjustments
TESTS AND ADJUSTMENTS REPAIR

Measuring Charge Pressure If the Turbocharger Does Not
The turbocharger charge pressure can be Operate:
measured using console digital display. 1. Check that there is no leakage or loose objects
Low charge pressure can be due to compressor in the line between the air cleaner and
wheel or turbine wheel damage, or dirt in the turbocharger.
compressor housing. 2. Check that there are no loose particles in the
exhaust or intake manifolds.
3. Check that all valves are intact.
4. Check the oil return line from the turbocharger
for blockage or deformity.
5. Check the oil supply line to the turbocharger for
any blockage, deformation and leakage under
pressure.
6. Check the condition and part number of the oil
filter.
7. Check that the air filter is not blocked and that
there are no other reasons for an abnormal
increase of vacuum in the intake system.
8. Check that engine output is correct. Excessively
high output reduces the service life of the
turbocharger.

Repair TURBOCHARGER
12/05
Remove Turbocharger Figure 9-48SY Engines

NOTICE: Observe strict cleanliness at all times (1)
when working on the turbocharger. Never leave
connections for oil inlets or outlets unprotected.
Foreign bodies in the bearing housing will lead to
turbocharger breakdown.
(1)
(1)
(2)
(2)
0003522
Figure 9-4
(2) 9. Remove the oil supply (Figure 9-3, (1)) or
(Figure 9-4, (1)) and return (Figure 9-3, (2)) or
(Figure 9-4, (2)) lines from the turbocharger.
Plug or cap all connections.
10. Drain one half of the coolant from the closed
cooling system until the coolant level is below
the level of the turbocharger.
0003520
Figure 9-3

TURBOCHARGER Repair
Figure 9-56SY Engines 13. Disconnect the exhaust pipe, induction pipe and
charge air cooler pipe from the turbocharger.
14. Remove the nuts retaining the turbocharger and
(1) remove the turbocharger.
Inspect the Turbocharger

Inspect the turbine and compressor wheels for
evidence of dirt, excess carbon build-up or damage
from a foreign object. Dirt and carbon can be
removed using a solvent-based cleaner. Damage to
either the turbine or compressor wheels will require
replacement of the turbocharger assembly.
NOTICE: Never attempt to straighten a damaged
vane. It may break off when running and the
turbocharger may stop operating completely,
(2)
causing serious damage to the engine.
Cleaning the Compressor

0003519 • Disassemble the compressor housing and clean
Figure 9-5 with mineral spirits and a brush.
Figure 9-68SY Engines • Replace the O-ring if it is damaged. Assemble the

compressor housing and measure the charging
pressure again.
(3) Measure the Radial and Axial

(1)
Clearance
In general, measuring the radial and axial
(1)
clearance gives no indication of the remaining
service life of the turbocharger.
When the turbocharger seems to be functioning
poorly or noisily, measuring the charging pressure
(3) or radial and axial clearance can indicate whether
(2)
the turbocharger is at fault.
(3)
It is advisable to remove the turbocharger to
(2) measure axial and radial clearances. Attach the
0003521
turbocharger to a steel plate, which will also serve
Figure 9-6 as a base for the magnetic stand holding the dial
indicator.
11. Remove the coolant supply (Figure 9-5, (2)) or
(Figure 9-6, (2)) and return (Figure 9-5, (1)) or
(Figure 9-6, (1)) lines from the turbocharger.
Plug or cap all connections.
12. Remove and discard O-rings (Figure 9-5, (3))
or (Figure 9-6, (3)).

Repair TURBOCHARGER
12/05
Radial Clearance 5. If any of the wheels makes contact with the

Take readings on both the turbine and compressor housing, despite the radial clearance reading,
wheels. the turbocharger must be replaced.
Figure 9-7
Axial Clearance
Figure 9-9
Figure 9-7
1. Place the tip of the dial indicator rocker against
the turbine / compressor wheel.
Figure 9-8
Figure 9-9
1. Place the tip of the dial indicator against the
end of the shaft.
2. Press the shaft longitudinally back and forth
and take a reading at the end positions. The
difference between the readings is the axial
clearance.
3. Repeat the test three times.
Specifications
Inspection Item Engine Limit
Turbocharger 6SY 0.198 - 0.564 mm
Shaft Radial (0.0078 - 0.0222 in.)
Clearance 8SY 0.611 mm
(0.0240 in.)
Turbocharger 6SY 0.025 - 0.106 mm
Shaft Axial (0.001 - 0.004 in.)
Clearance 8SY 0.102 mm
Figure 9-8
(0.004 in.)
2. Pull up both ends of the shaft. Take a reading.
3. Press down both ends of the shaft. Take a
reading. The difference between the readings is
the radial clearance.
4. Repeat the test three times on each side.

TURBOCHARGER Repair
Install the Turbocharger Figure 9-118SY Engines

Note: When installing the turbocharger, replace (1)
all gaskets with new ones. Change the
oil filter and clean the centrifugal oil
cleaner.
1. Clean the connecting flange on the exhaust
manifold of all old gasket material. (1)
2. Install a new gasket. Lubricate the turbocharger

mounting studs with temperature resistant
lubricant, OEM Part No. 561 205 (or similar (2)
tool). Install the turbocharger on the exhaust
manifold and tighten nuts to:
• 6SY: 50 N·m (37 ft-lb)
• 8SY: 63 N·m (46 ft-lb)
(2)
0003522
(1)
Figure 9-11
3. Connect the oil supply (Figure 9-10, (1)) or
(Figure 9-11, (1)) and return (Figure 9-10, (2))
or (Figure 9-11, (2)) lines.
(2)
0003520
Figure 9-10

Repair TURBOCHARGER
12/05
Figure 9-126SY Engines 5. Connect the charge air pipe, induction pipe and
exhaust pipe. Tighten to:
• V-Clamp - M6 Bolt: 8 N·m (71 in.-lb)
(1) • V-Clamp - M8 Bolt: 20 N·m (177 in.-lb)
• Exhaust Pipe Flange Bolt: 24 N·m (212 in.-lb)
6. Install a new oil filter and clean the centrifugal
oil cleaner.
7. Start the engine and keep speed at idle until
normal oil pressure is reached. NOTICE: DO
NOT raise engine speed above idle until normal
oil pressure is reached. Damage to the
turbocharger bearings and other engine
components could result.
(2) 8. Start the engine and check for oil, water and
exhaust leakage.
0003519
Figure 9-12
(3)
(1)
(1)
(3)
(2)
(3)
(2)
0003521
Figure 9-13
4. Install new O-rings (Figure 9-12, (3)) or
(Figure 9-13, (3)) and connect the coolant
supply (Figure 9-12, (2)) or (Figure 9-13, (2))
and return (Figure 9-12, (1)) or (Figure
9-13, (1)) lines.

TURBOCHARGER Repair

Section 10
STARTER MOTOR
Page
Before You Begin Servicing .......................................................... 10-3
Introduction.................................................................................... 10-4
Starter Motor Specifications .......................................................... 10-5
Starter Motor Troubleshooting....................................................... 10-6
Remove and Install Starter Motor.................................................. 10-7
Repair Starter Motor - Bosch JE ................................................... 10-8
Components ............................................................................ 10-8
Brush Replacement ............................................................... 10-10
Replace Solenoid .................................................................. 10-11

STARTER MOTOR

Before You Begin Servicing STARTER MOTOR
12/05
BEFORE YOU BEGIN

SERVICING NEVER engage the starter motor while the engine
is running. Damage to the starter motor pinion and /
or ring gear will result.
ALWAYS turn off the battery switch (if equipped) or
disconnect the negative battery cable before
servicing the electrical system.
ALWAYS check the electrical harnesses for cracks,

abrasions, and damaged or corroded connectors.
ALWAYS keep the connectors and terminals clean.

STARTER MOTOR Introduction
INTRODUCTION
This section of the Service Manual covers the
servicing of starter motor. Yanmar Part No.
165000-29830 is standard equipment on 6SY and
8SY model engines and is used in this section to
show the service procedures for a representative
starter motor. For specific part detail, see the
Yanmar Parts Catalog for the engine being
serviced.

Starter Motor Specifications STARTER MOTOR
12/05
STARTER MOTOR SPECIFICATIONS

Item Bosch JE
Power 6.7 kW (4942 ft-lb/s)
Direction of Rotation (Viewed toward flywheel housing) Counterclockwise
Brush Length (Minimum) 17.5 mm (0.689 in.)
Brush Spring Pressure 47 - 53 N (10.5 - 12.0 lbf)
Solenoid Pull-in Winding Resistance 0.5 ohms
Solenoid Hold-in Winding Resistance 2.5 ohms
Armature Radial Run-out (Maximum) 0.10 mm (0.004 in.)
Commutator Radial Run-out (Maximum) 0.03 mm (0.001 in.)
Commutator Diameter (Minimum) 42.5 mm (1.673 in.)

Item Bosch JE
Battery Positive (+) Cable 24 - 32 N·m (17 - 24 ft-lb)
Control Cable 2 - 3 N·m (18 - 27 in.-lb)
Ground Cable-to-Starter Housing 16 - 20 N·m (142 - 177 in.-lb)

Figure 10-1
10-6
Is the shift lever at NO Move shift lever to Is battery fully charged NO • Charge or replace battery.
NEUTRAL position? NEUTRAL position. and terminals clean? • Clean terminals.
YES
Engine does not start? Inspect wiring up to solenoid switch
Is starter motor solenoid and repair if necessary.
NO
STARTER MOTOR
switch actuating sound • Key switch

YES heard? • Safety relay
• Solenoid switch assembly
NO NO • Electrical connections
Does engine crank? Is starter motor operating? YES
YES
• Adjust / pinion projection length.
• Inspect shift lever for deformation,
Pinion and ring gear NO return spring for fatigue and pinion
meshing normal? for sliding.
YES • Repair meshing between pinion and
ring gear or replace as needed.
YES
Connect M terminal of starter NO • Inspect brush and replace if worn.
Pinion roller clutch or motor directly to battery. • If brushes are not worn, replace armature
reduction gear damaged. Does starter motor operate? assembly.
Inspect and replace.
YES
Solenoid switch assembly If starter motor becomes wet, replace solenoid switch
Figure 10-1
contact defective. Repair assembly even if function is normal.
NO or replace.
STARTER MOTOR TROUBLESHOOTING
(slow revolution) NO
Is revolution normal? Is battery fully charged • Charge or replace battery. If a problem occurs:
and terminals clean? • Clean terminals. Immediately disconnect battery negative terminal.
YES YES
Inspect fuel system. Is the engine oil NO Engine does not stop
Replace engine oil.
viscosity correct? even when key switch is
turned OFF.
YES
Does engine turn when YES Repair or replace Repair or replace key switch, starting
starter motor is replaced? starter motor.

motor relay or magnetic switch assembly.
Slow Revolution
Inspect condition of engine.
0000102
Starter Motor Troubleshooting
Remove and Install Starter Motor STARTER MOTOR
12/05
REMOVE AND INSTALL • Primary wire (Figure 10-2, (3)). Tighten to

2 - 3 N·m (18 - 27 in.-lb).
STARTER MOTOR • Battery positive (+) (Figure 10-2, (2)). Tighten
1. Disconnect the battery(s), negative (-) cable to 24 - 32 N·m (17 - 24 ft-lb).
first or turn off the battery master switch. • Ground cable (Figure 10-2, (3)). Tighten to
Figure 10-2
(2) 16 - 20 N·m (142 - 177 in.-lb).

30 12. Connect the battery, negative (-) cable first, or
(3)
return the master switch to the ON position.
50
13. Install any panels or housings removed to
access the starter.
14. Operate starter to verify operation.
(1)
31
0002240
Figure 10-2
Note: The dotted conductor wire shows ground
connection for the solenoid switch on
2-pin starter motors.
2. Disconnect ground cable (Figure 10-2, (1)) if
used.
3. Disconnect positive (+) cable (Figure 10-2, (2))
and primary wire (Figure 10-2, (3)).
4. Move cables to one side.
5. Remove bolts holding the starter motor to the
flywheel housing.
6. Carefully remove the starter motor. WARNING!
The starter motor is heavy. Use care when
removing the starter motor.
7. Inspect the starter motor. NOTICE: Check the
starter pinion for damage. If the starter pinion is
damaged, the flywheel ring gear must also be
checked for damage.
8. Clean the starter mounting area of the flywheel
housing.
9. Install the starter motor.
10. Clean the cable connections.
11. Connect the cables to the appropriate
terminals:

STARTER MOTOR Repair Starter Motor - Bosch JE
REPAIR STARTER MOTOR - BOSCH JE

Components
Figure 10-3
(5)
(6)
(1) (3)
(4)
(2)
(7)
(8)
(9)
(11) (13)
(10)
(14)
(12)
(15)
(16)
(22)
(21)
(17)
(19) (18)
(20)
0002241
Figure 10-3

Repair Starter Motor - Bosch JE STARTER MOTOR
12/05
1 – Front Housing 12 – Electrical Stud and Insulator

2 – Pinion Gear 13 – Field Housing
3 – Engaging Lever 14 – Through-Bolt
4 – Intermediate Bearing 15 – Rear Cover
5 – Solenoid Assembly 16 – Shim Washers and Gasket
6 – Conducting Bar 17 – Rear Bearing Housing
7 – O-Ring 18 – O-Ring
8 – Bearing 19 – Brush Spring
9 – Armature 20 – Brush Kit
10 – Bearing 21 – Brush Holder Assembly
11 – Bearing 22 – Field Winding

Brush Replacement 6. Remove positive brush wire connection screws

(Figure 10-5, (2)).
Equipment Required 7. Install the spring locks (Figure 10-5, (3)) to
Four spring locks are required to replace the relieve spring pressure on the brushes.
brushes and springs. Make from thin sheet metal 8. Remove the brush holder and brushes.
cut into four pieces approximately 20 x 40 mm.
9. Inspect the commutator for damage, burned
Repair areas, or wear.
Figure 10-6
1. Remove starter. See Remove and Install

Figure 10-4
(3)
(2)
0002244
(1)
0002242
Figure 10-6
Figure 10-4 10. Remove the brushes and springs using a
2. Mark the position (Figure 10-4, (1)) of the rear screwdriver (Figure 10-6). CAUTION! The
bearing housing with a marker. brush springs are under considerable
tension when installing or removing from
3. Remove the rear cover (Figure 10-4, (2)). the brush housing and can unexpectedly
4. Remove the through-bolts (Figure 10-4, (3)) come out. ALWAYS wear safety glasses
and rear bearing housing. when repairing the recoil starter.
Figure 10-5
11. Place new brushes in the brush holder. Do not

install the springs yet.
(3) 12. Install the brush holder and align the mark
made during disassembly. Connect the brush
wires.
(2)
(1)
0002243
Figure 10-5
5. Mark the position of the brush holder (Figure
10-5, (1)).

Repair Starter Motor - Bosch JE STARTER MOTOR
12/05
Replace Solenoid
Figure 10-7
1. Remove starter. See Remove and Install

Figure 10-8
(1)
(2)
0002245
Figure 10-7
13. Install new springs. Use a small screwdriver in
the center of the spring to coil it and slide it onto
the post (Figure 10-7).
• Set the brush in position.
• Coil the spring one half turn.
0002246
• Press the center of the spring onto the post.
Figure 10-8
14. Install the end housing using the spring locks to
relieve spring pressure on the brushes. Align 2. Remove the solenoid conducting bar.
the marks made during disassembly. 3. Remove four bolts and the solenoid housing.
15. Install the rear cover and seal. 4. Remove the plunger assembly (Figure
16. Install starter. See Remove and Install Starter 10-8, (1)).
Motor on page 10-7. 5. Apply heat-resistant grease to the plunger
surfaces that engage the coupling lever (Figure
10-8, (2)).
6. Install the plunger assembly making sure that it
engages the coupling lever.
7. Lightly lubricate the plunger with a
heat-resistant grease.
8. Install the solenoid housing and secure with
four screws.
9. Install the conducting bar and tighten terminal
nuts to specification.
10. Install starter. See Remove and Install Starter
Motor on page 10-7.


Section 11
ALTERNATOR
Page
Before You Begin Servicing .......................................................... 11-3
Introduction.................................................................................... 11-4
Specifications ................................................................................ 11-5
Calculating Alternator Capacity ..................................................... 11-6
Alternator and Charging System Troubleshooting ........................ 11-6
Test and Inspection ....................................................................... 11-7
Output Test.............................................................................. 11-7
Brush Length ........................................................................... 11-8
Rotor........................................................................................ 11-8
Repair............................................................................................ 11-9
Replace Alternator Belt............................................................ 11-9

ALTERNATOR

Before You Begin Servicing ALTERNATOR
12/05
BEFORE YOU BEGIN

SERVICING NEVER operate the engine if the alternator is
producing unusual sounds. Damage to the
alternator will result.
ALWAYS turn off the battery switch (if equipped) or
disconnect the negative battery cable before NEVER turn the battery switch OFF while the
servicing the electrical system. engine is operating. Damage to the alternator will
result.
ALWAYS check the electrical harnesses for cracks,
abrasions, and damaged or corroded connectors. NEVER reverse the positive (+) and negative (-)
ALWAYS keep the connectors and terminals clean. ends of the battery cable. The alternator diode and
stator coil will be damaged.
NEVER use a high-pressure wash directly on the

alternator. Water will damage the alternator and
result in inadequate charging.
NEVER operate the engine if the alternator is

producing unusual sounds. Damage to the
alternator will result.
NEVER turn the battery switch OFF while the

engine is operating. Damage to the alternator will
result.
NEVER use a high-pressure wash directly on the

alternator. Water will damage the alternator and
result in inadequate charging.

ALTERNATOR Introduction
INTRODUCTION
This section of the Service Manual describes
servicing of the 6SY and 8SY charging systems.
Yanmar 6SY and 8SY marine engines can be
equipped with one or two alternators, depending on
system requirements.
• Ensure correct polarity when connecting the
batteries. The alternator diodes will be damaged
if the polarity is reversed.
• It is not necessary to disconnect any leads to the
alternator for electric welding. Attach the welder’s
ground clamp as close as possible to the welding
point.

Specifications ALTERNATOR
12/05
SPECIFICATIONS
Item Bosch (65A) Bosch (140A)
Manufacturer’s Number N1-28V 20/65A T1-28V 70/14A
Output at 6000 RPM (alternator speed) 1800W *
System Voltage 24 V, Negative Ground 24V, Negative Ground

Drive Ratio 3.5:1 *
Output Test Amperage@28 V * *
Output Test Voltage 27.5-28.5 V *
Brush Length (Minimum) 7.5 mm (0.295 in.) *
Slip Ring Diameter (Minimum) 26.8 mm (1.055 in.) *
Rotor Resistance 8.4 - 8.8 ohms *
Stator Resistance 0.3 ohm *

Item Bosch 65A Bosch 140A
Belt Pulley Nut 65 N·m (48 lb·ft) *

ALTERNATOR Calculating Alternator Capacity
CALCULATING ALTERNATOR Alternator Current Output (approximate)

with 3.5:1 Drive Ratio
CAPACITY
RPM Bosch (65A)
Some engines or aggregates have a considerable
Engine Alternator Output (Amps)
level of equipment with high current consumption.
500 1750 31
It is essential that the alternator capacity is adapted 600 2100 40
to the consumption in question. If the alternator 700 2450 46
capacity is too low, battery life will be impaired and
800 2800 50
cause possible starting difficulties.
900 3150 53
The alternator must be able to deliver an excess 1000 3500 56
charge of at least 10 A. In principle, the batteries 1100 3850 58
are intended for starting the engine.
1200 4200 60
1. Add together the engine or aggregate current 1300 4550 61
consumers that can be engaged simultaneously 1400 4900 63
when in operation. Add to this value at least 1500 5250 64
10 A.
1600 5600 64
Example: 1700 5950 65
If there is a consumption of 40 A, the alternator 1800 6300 65
must be capable of outputting 50 A. 1900 6650 66
2000 7000 66
1. Determine the relevant type of operation.
Long-term service has fewer stops and 2100 7350 67
therefore requires a lower alternator capacity 2200 7700 67
than an engine or aggregate with many stops. 2300 8050 67
Look up the required alternator capacity in the 2400 8400 67
diagram on the right.
The current generated by the alternator is
dependent on the engine speed. The table below ALTERNATOR AND CHARGING
shows the approximate current delivered by the
alternator at various engine speeds. SYSTEM TROUBLESHOOTING
If a fault code is present that indicates a
malfunction in the alternator or charging system,
follow the procedures in the Fault Codes on
page 13-18.

Test and Inspection ALTERNATOR
12/05
TEST AND INSPECTION

Figure 11-1
(5)
D+
Output Test W
B−
1. Connect a calibrated test instrument with load
B+
resistor as illustrated in (Figure 11-1). NOTICE:
(4)
NEVER operate the engine with the batteries
(3)
disconnected. Damage to the alternator will
result.
Note: A digital clip-on ammeter can also be V A
connected to the B+ wire at the

alternator for a more precise reading.
2. Start the engine and let it run for a few minutes (2)
(1)
before carrying out the test.
3. Increase the engine speed to 1715 rpm, (7)
(6000 rpm alternator speed). Apply current to
the load resistor. Record voltage and current
output.
Note: The following steps must be performed (6)
with fully charged batteries.
4. Remove the load and allow the engine to run
0002254
until the alternator is delivering approximately
5A at the battery.
1 – Test Instrument Equipped with Voltmeter,
5. Again record voltage. Ammeter and Load Resistor
2 – Connection to Load Resistor
Specifications
3 – Clip for Current Reading
Inspection Item Bosch (65A) 4 – Connection to Voltmeter
Test Output Amperage@28 V * 5 – Alternator
6 – Starter Motor
Test Output Voltage 27.5 - 28.5 V
7 – Batteries
*Not available at time of publication. Figure 11-1

ALTERNATOR Test and Inspection
Brush Length Rotor

0002256
0002255
Figure 11-3
Figure 11-2
Slip Rings
The brush holder is attached to the charge
The slip rings must be bright metal across their
regulator. The brushes must be checked for
whole surface. Dull slip rings indicate bad contact
damage and length. The ends must be bright and
with the brushes. The slip rings can be accessed
rounded so they fit against the slip rings.
after removing the charge regulator.
Brush length is measured between the end of the
brush and the brush holder. Resistance
Measure the rotor resistance using an ohmmeter
Specifications between the slip rings.
Inspection Item Bosch 65A
Specifications
Brush Length (minimum) 7.5 mm (0.295 in.)
Inspection Item Bosch 65A
Rotor Resistance 8.4 - 8.8 ohms
When measuring between the slip rings and the

core, the ohmmeter must show infinite resistance
(at least 10 megaohms).

Repair ALTERNATOR
12/05
REPAIR Figure 11-58SY Engines
Replace Alternator Belt

(3) (6)
(4)
(2)
(4)
(1)
(5) 00026
0004669
1 – Crankshaft Belt Pulley
2 – Belt Tensioner Figure 11-5
3 – Coolant Pump
4 – Alternator 1. Install a 1/2-inch drive breaker bar in the square
5 – Alternator Belt hole of the belt tensioner.
6 – Idler Roller
2. Rotate the tensioner to relieve belt tension.
Figure 11-4 Remove belt.
Note: 6SY with dual alternators shown. 3. Installation is the reverse of removal.

ALTERNATOR Repair

Section 12
EMS
Page
Introduction.................................................................................... 12-3
Specifications .......................................................................... 12-3
Special Service Tools.................................................................... 12-3
Function Description - Engine Management System (EMS S6).... 12-4
General.................................................................................... 12-4
Component Location ............................................................... 12-5
Engine Speed Sensors - T28 and T29 .................................... 12-7
Charge Air Pressure and Temperature Sensor - T26.............. 12-8
Coolant Temperature Sensor - T27....................................... 12-10
Oil Pressure Sensor - T25 ..................................................... 12-11
EMS S6 Control Unit E44 ...................................................... 12-12
EMS S6 Control Unit Connections ........................................ 12-13
Repair.......................................................................................... 12-17
Replace the EMS S6 Control Unit ......................................... 12-17
Remove the EMS S6 Wiring.................................................. 12-17
Installing EMS S6 Wiring ....................................................... 12-20

EMS

Introduction EMS
12/05
INTRODUCTION
This section of the Service Manual describes the operation of and procedures to replace the components
of the Engine Management System as used on the Yanmar 6SY and 8SY marine engines.
Specifications
Lubricating Oil
Application (Thread
Portion and Seat
Surface)
Injector Electrical Terminal Screw 2 N·m Not Applied See Installing EMS S6
(283 in.-oz) Wiring on page 12-20
Rocker Cover Bolt (Upper and Lower Cover) 26 N·m (19 ft-lb) Not Applied

No. Tools not having part numbers must be acquired locally.
No Tool Name Applicable Model and Tool Size Illustration

1 Torque OEM Part No. 288 179
Screwdriver (For
Connecting
Cables to
Injector)

EMS Function Description - Engine Management System (EMS S6)
FUNCTION DESCRIPTION -
ENGINE MANAGEMENT
SYSTEM (EMS S6)
General
Figure 12-1 illustrates the components and
systems with which the EMS S6 control unit
communicates.
Communication with certain components must take
place via a coordinator (Teleflex i8310).
Figure 12-1
i8310
0003167
1 – Engine Speed Sensors (2 used)

2 – Charge Air Pressure and Temperature
Sensor
3 – Coolant Temperature Sensor
4 – Oil Pressure Sensor
5 – Unit Injector Solenoid Valves (one per
cylinder)
Figure 12-1

Function Description - Engine Management System (EMS S6) EMS
12/05
Component Location
6SY Engines
Figure 12-2
(1) (2)
(3)
(6)
(4) 16:6028A
(5)
1 – Oil Pressure Sensor 4 – Coolant Temperature Sensor

2 – Charge Air Pressure and Temperature 5 – Engine Speed Sensor
Sensor 6 – Unit Injector Solenoid Valves
3 – EMS S6 Control Unit
Figure 12-2

8SY Engines
Figure 12-3
(1)
(2)
(6)
(3)
(4)
(5)
0003200
1 – Oil Pressure Sensor (Optional Combination 4 – Charge Air Pressure and Temperature
Oil Pressure and Oil Temperature Sensor Sensor
Available) 5 – Engine Speed Sensor
2 – Coolant Temperature Sensor 6 – EMS S6 Control Unit
3 – Unit Injector Solenoid Valves
Figure 12-3

12/05
Engine Speed Sensors - T28 and T29 There are two engine speed sensors in the EMS S6
system; Engine Speed Sensor 1 and Engine Speed
Figure 12-46SY Engine Sensor 2. The sensors are inductive, meaning they
only produce signals when the engine is running.
The signal strength varies significantly depending
on the air gap between the sensors and the
flywheel, as well as engine speed. The EMS S6
(2)
system performs an assessment of the signal
strength at different engine speeds. If the signal
(1)
strength becomes too low, a fault code is
generated.
Both engine speed sensors read the position of the
flywheel. This means that the system cannot
determine which of two possible revolutions the
engine is at: for example, whether cylinder 1 or
cylinder 6 is at the ignition position. Every time the
engine is stopped and the voltage removed, the
crankshaft position is stored. Next time the voltage
is switched on, the stored position of the crankshaft
0003447
is used to determine which revolution the engine is
1 – Engine Speed Sensor 1, T28 at. When the engine has started, a system check is
2 – Engine Speed Sensor 2, T29 performed to verify that the stored position is
correct.
Figure 12-4
The EMS S6 control unit receives signals from both
Figure 12-58SY Engine engine speed sensors. If the control unit receives a
faulty signal or no signal from either of the engine
speed sensors, the engine torque is limited for
safety reasons. If the control unit receives a correct
signal, the engine will operate normally again.
If the control unit receives a faulty signal or no
signal from both engine speed sensors, the engine
cannot be started. If the engine is running, it will
stop.
(1)
0003448
(2)
1 – Engine Speed Sensor 1, T28
Figure 12-5

Figure 12-7Sensor Connections to EMS S6

Figure 12-6
(1) (2)
1 – Engine Speed Sensor 1, T28 Figure 12-7

Charge Air Pressure and
Figure 12-6
Temperature Sensor - T26
The engine speed sensors detect the holes in the
flywheel when the flywheel rotates and send pulses Figure 12-86SY Engines
to the control unit at every hole. This allows the
control unit to calculate where in the operating
cycle the engine is. The control unit senses and
compares the engine speed at combustion in each
cylinder. The control unit attempts to keep the
engine speed constant by adjusting the fuel volume
individually for each cylinder.
The interval between two of the holes is greater
than that between the remaining holes. When the
control unit senses that this larger interval passes
the sensor, it knows that the flywheel is in a specific
position in relation to top dead center (TDC up).
If the control unit detects any faults, one or more
fault codes are generated. Figure 12-8

12/05
Figure 12-98SY Engines Charge Air Temperature Sensor

The charge air temperature sensor detects the
intake air temperature. The control unit uses the
signal from the sensor to finely adjust the fuel
quantity so that black smoke is not produced. The
warmer the charge air, the less fuel the control unit
allows to the unit injectors.
The sensor is of the NTC type, meaning its
resistance is temperature dependent. If the
temperature increases, the resistance in the sensor
Figure 12-9 drops.
The sensors for charge air pressure and If the voltage is outside a certain range, the control
temperature are integrated into one single unit will operate according to a preset temperature
component. value.
Charge Air Pressure Sensor The engine will then react more slowly than normal
The charge air pressure sensor detects the when actuating the throttle in cold weather, as the
absolute pressure in the intake manifold, which control unit thinks that the air is warmer than it
consists of the atmospheric pressure plus the actually is.
overpressure provided by the turbocharger. Figure 12-10Sensor Connection to EMS S6
The EMS S6 control unit uses the signal from the
sensor to limit the fuel volume when the charge air
pressure is below a certain level. The lower the
pressure, the less fuel the control unit allows to the
unit injectors, avoiding black exhaust smoke.
The control unit reads the voltage from the sensor.
The signal voltage is directly proportional to the
charge air pressure. High pressure gives high
voltage and vice versa.
Depending on factors such as throttle actuation,
engine speed, engine acceleration and charge air
temperature, the control unit will expect a certain
value for the charge air pressure.
If there are any faults in the signal, the control unit
Figure 12-10
will operate according to a preset pressure value.
As a safety precaution, the engine torque is then
limited.

Coolant Temperature Sensor - T27 The coolant temperature sensor affects the fuel
volume and injection timing when starting the
Figure 12-116SY Engines engine and when the engine is cold. It also affects
the engine idling speed and maximum engine
speed when the engine is cold and the engine
power when it is too warm.
If the coolant temperature sensor senses that the
engine is cold when attempting to start (cold start),
the engine will make a few turns without any fuel
being injected to heat up the cylinders and then the
amount of fuel injected will gradually increase until
the engine starts.
Directly after a cold start, the engine speed is
limited to 1000 rpm to protect the engine.
The length of time engine speed limitation is
engaged varies depending on the coolant
temperature:
Below -10°C (+14°F) 30 seconds

Above +20°C (+68°F) 1 second
Between -10° to +20°C Linear
(+14° to +68°F) 1-30 seconds
Figure 12-11
The engine idling speed returns to normal when the
Figure 12-128SY Engines coolant has reached +20° to +60°C
(+68° to +140°F). The temperature limits will differ
between engine types.
Figure 12-13Sensor Connection to EMS S6
Figure 12-12
Figure 12-13

12/05
The control unit reads the voltage from the sensor. Oil Pressure Sensor - T25
If the voltage is outside a certain range, the control
unit will operate according to a preset temperature Figure 12-15 6SY Engines
value. The engine will then have poorer cold start
characteristics and will emit more white smoke in
cold weather.
Figure 12-14Power vs. Engine Temperature
Figure 12-14
On certain engines, the engine power is limited
when the coolant temperature exceeds 104°C Figure 12-15
(219°F). Engine power is limited to prevent further
engine overheating, and a fault code is generated
at the same time (Figure 12-25).
Figure 12-16
The oil pressure sensor measures engine oil
pressure.

The control unit reads the voltage from the sensor. EMS S6 Control Unit E44
If the signal voltage is outside a certain range, the
oil pressure gauge on the instrument panel will Function of EMS S6 Control Unit
show 2.5 bar (36 psi), regardless of engine speed,
and a fault code will be generated at the same time. Figure 12-186SY Engines
The control unit expects a certain oil pressure

depending on the engine speed. Below 1000 rpm,
the oil pressure should be at a certain level. Above
1000 rpm, the oil pressure should be at a higher
level, in order to provide sufficient oil pressure for
piston cooling, etc. If the oil pressure is below the
expected value, a warning alarm is sounded. The
oil pressure warning alarm will sound at different
pressure levels depending on the engine speed.
As an option on 8SY marine engines, a
dual-purpose sensor is available that measures
both oil pressure and oil temperature. It is located
in the same place as the oil pressure-only sensor.
Figure 12-17Connection to EMS S6 Figure 12-18
Figure 12-17
Figure 12-19
The EMS S6 control unit collects information which
it processes into signals that control the fuel volume
and injection timing.
The control unit converts the system voltage to a
voltage of approximately 5 V, which it supplies to
sensors, etc. These sensors are always grounded
through the control unit.

12/05
EMS S6 Control Unit Connections

The EMS S6 control unit is connected to other components and systems via connectors A and B (Figure
12-31). The following graphic and table show the pin locations and assignments.
Figure 12-20
(1) (1)
(2) (2)
(4) (3) (4) (3)
(5) (5) (6) (5)
(6) (7) (8) (7)
(9) (9)
(10) (10)
0003450
Figure 12-20

EMS S6 Control Unit Pin Assignments

Connector Pin Assignment Detail
A1 (6SY / 8SY) 1 Voltage supply, +24 V to unit injectors 8SY cylinder 8
6SY cylinder 4
6SY cylinder 5
A1 (6SY / 8SY) 3 Not used
6SY cylinder 6
A1 (6SY / 8SY) 6 Ground for unit injectors 8SY cylinder 8
6SY cylinder 4
6SY cylinder 5
A1 (6SY / 8SY) 8 Not used
6SY cylinder 6
A2 1 Not used
A2 2 Not used
A2 3 Not used
A2 4 Not used
A2 5 AUX_AN_0, Extra analog input (Ground)
A2 6 Not used
A2 7 AUX_AN_1, Extra analog input (+5V)
A2 8 AUX_AN, Extra analog input (Signal)
A2 9 Not used
A2 10 Not used
A3 1-2 Not used
A4 1-2 Not used
A5 1 Input signal from engine speed sensor 1
A5 2 Ground for engine speed sensor 1
A6 1 Input signal from engine speed sensor 2
A6 2 Ground for engine speed sensor 2
A7 1 Input signal from the coolant temperature sensor
A7 2 Ground for coolant temperature sensor
A8 1-2 Not used
A9 1 Input signal from the oil temperature sensor. The control
unit detects the voltage level between pins 1 and 4 (8SY
marine engine only).
A9 2 Voltage supply, +5V to the oil pressure sensor
A9 3 Input signal from the oil pressure sensor. The control unit
detects the voltage level between pins 3 and 4.

12/05

A9 4 Ground for oil pressure sensor
A9 5 Not used
A10 1 Voltage supply, +5V to the charge air pressure sensor
A10 2 Input signal from the charge air pressure sensor. The
control unit detects the voltage level between pins 2 and
3.
A10 3 Ground for charge air pressure sensor
A10 4 Input signal from the charge air temperature sensor. The
control unit detects the voltage level between pins 3 and
4.
A10 5 Not used
B1 1 Voltage supply, +24V to the control unit
B1 2 Ground connection for the control unit to chassis
B1 3 Input signal +24V, from the ignition lock
(when the key is in the drive position)
B1 4 Not used
B1 5 Not used
B1 6 Voltage supply, +24V to the control unit
B1 7 Ground connection for the control unit to chassis
B1 8 Not used
B1 9 CAN communication, H lead
B1 10 CAN communication, L lead
B2 (6SY / 8SY) 1 Voltage supply, +24V to unit injectors 8SY cylinder 1
6SY cylinder 1
6SY cylinder 2
B2 (6SY / 8SY) 3 Not used
6SY cylinder 3
B2 (6SY / 8SY) 6 Ground for unit injector 8SY cylinder 1
6SY cylinder 1
B2 (6SY / 8SY) 7 Ground for unit injector 8SY cylinder 2
6SY cylinder 2
B2 (6SY / 8SY) 8 Not used
B2 (6SY / 8SY) 9 Ground for unit injector cylinder 3 8SY cylinder 3
6SY cylinder 3
B2 (6SY / 8SY) 10 Ground for unit injector cylinder 4 8SY cylinder 4
B3 1-2 Not used
B4 1-2 Not used
B5 1-2 Not used
B6 1-2 Not used
B7 1 Not used


B7 2 Not used
B8 1-2 Not used
B9 1-5 Not used
B10 1-5 Not used

Repair EMS
12/05
REPAIR 2. Remove the control unit attaching screws and

remove the control unit.
Replace the EMS S6 Control Unit 3. Install the new control unit and tighten the
screws to 22 N·m (195 in.-lb).
Figure 12-21 6SY Engines
4. Plug in the connectors on the control unit.
5. Perform the necessary programming with the
diagnostic tool. Start the engine. Check the fault
codes and delete them.
Remove the EMS S6 Wiring

1. Drain coolant from the engine. WARNING! Wait
until the engine cools before you drain the
engine coolant. Hot engine coolant may
splash and cause burns.
2. Remove upper rocker covers. See Remove and
3. Disconnect the connectors from the control unit.
4. Mark the cables with the respective cylinder
Figure 12-21 numbers.
5. Disconnect the cables from the unit injectors.
Figure 12-228SY Engines The screws cannot be removed, but they should
be unscrewed as far as possible.
Figure 12-23
1. Remove the covers over the connectors on the 6. Remove cables from each cylinder head
control unit and unplug the connectors. (Figure 12-34).
NOTICE: The EMS S6 control unit may be • 6SY: Remove the cable duct to which the
damaged if it is powered when you unplug it. cables are attached. Remove the cable
Before removing the control unit, the key switch bushings in the lower rocker covers and
must be turned off before removing harness remove the cables.
connectors.

EMS Repair
• 8SY: Remove the bushings from the lower Figure 12-258SY Engines
rocker covers. Pull out the cables from the
rocker covers and lift off the cable ducts. (1)

(1) (3) (2)
(3)
Figure 12-25
7. Remove the charge air sensor (Figure
12-24, (3)) or (Figure 12-25, (3)) and clamps.
NOTICE: Handle the engine sensors with care.
(2) They are magnetic and are sensitive to impacts.
8. Remove the oil pressure sensor (Figure
9. Remove the coolant temperature sensor
(Figure 12-24, (2)) or (Figure 12-25, (2)) and
16:6027 A
clamps.
Figure 12-24

Repair EMS
12/05
(1)
Figure 12-26 026A
(1)
Figure 12-27
10. Remove both engine speed sensors (Figure

EMS Repair
Installing EMS S6 Wiring

Figure 12-28Wiring and Cable Duct - 6SY
(7) (6)
(5)
(1)
(4)
(3)
(2)
0003451
1 – Cylinders 1 - 6 5 – Connector to Control Unit

2 – Coolant Temperature Sensor 6 – Charge Air Pressure and Temperature
3 – Engine Speed Sensor 1 Sensor
4 – Engine Speed Sensor 2 7 – Oil Pressure Sensor
Figure 12-28
Figure 12-29Wiring and Cable Ducts - 8SY

(5) (6) (7)
(4)
(1) (1)
(3) (2) 0003449
1 – Cylinders 1 - 8 5 – Coolant Temperature Sensor

2 – Engine Speed Sensor 1 6 – Oil Pressure Sensor
3 – Engine Speed Sensor 2 7 – Charge Air Pressure and Temperature
4 – Connectors to Control Unit Sensor
Figure 12-29

Repair EMS
12/05
• Make sure that the inlet pipe between the

Figure 12-30
turbocharger and the air cleaner has been

removed.
• Install the cable ducts. Schematic illustrations of
of the cable ducts and their components on each
engine are shown in Figure 12-26 and Figure
12-27.
1. Run the cables to the unit injectors.
2. Check that the correct cable is connected to
each unit injector by testing the cables with a
107 519
multimeter as shown in the tables below.
6SY Engine
Figure 12-30
Cylinder Connector Pin
3. Press the cables into the groove in the lower
1 B2 1 and 6
rocker cover (Figure 12-30).
2 B2 2 and 7 Figure 12-31
3 B2 4 and 9
4 A1 1 and 6
5 A1 2 and 7
6 A1 4 and 9
(1)
8SY Engine
Cylinder Connector Pin
1 B2 1 and 6
2 B2 2 and 7
3 B2 4 and 9
4 B2 5 and 10
5 A1 5 and 10
118 482A
6 A1 4 and 9
7 A1 2 and 7
8 A1 1 and 6 Figure 12-31
4. Install wire terminals. NOTICE: Ensure injector
wire terminals are installed with the bosses
(Figure 12-31, (1)) facing up.

EMS Repair

Figure 12-32
(3)
(1)
Figure 12-32
5. Connect wires to the unit injectors. Their
relative position is not important. Use torque
screwdriver OEM Part No. 588 179 (or similar
tool) to tighten screws to 2 N·m (283 in.-oz)
(Figure 12-32). NOTICE: Do not over-tighten
the cable connection screws on the unit injector.
If a screw breaks, the unit injector must be
replaced.
6. 8SY engines: Attach the bushings and cable
ducts to the lower rocker covers. (2)
(4)
Figure 12-33

Repair EMS
12/05
(1)
(2)
(3)
Figure 12-34
7. Install the oil pressure sensor (Figure
NOTICE: Handle the engine sensors with care.
They are magnetic and are sensitive to impacts.
8. Install the coolant temperature sensor (Figure
9. Install the charge air sensor (Figure 12-33, (3))
or (Figure 12-34, (3)) and clamps.
10. Install the engine speed sensors and clamps.
11. Connect ECOM to the engine and check the
unit injectors by activating them. Also check that
the values from the sensors are correct.
12. Connect the wiring harness connectors into the
control unit.
13. Install the upper rocker covers. See Remove
and Install Rocker Covers on page 5-23.
14. Install the inlet pipe between the turbocharger
and the air cleaner.
15. Fill engine with coolant.

EMS Repair

Section 13
TROUBLESHOOTING
Page
Introduction.................................................................................... 13-3
Troubleshooting Chart................................................................... 13-3
Fault Codes ................................................................................. 13-18
Working Procedure................................................................ 13-18
After Troubleshooting or Repair .................................................. 13-18

TROUBLESHOOTING

Introduction TROUBLESHOOTING
12/05
INTRODUCTION
This section contains information and diagnostic troubleshooting charts to accurately diagnose and engine,
starter, or alternator problem.
TROUBLESHOOTING CHART
White Smoke
Effect Cause Troubleshooting Action
Incompletely burned fuel Cold engine The white smoke starts to turn If possible: reduce engine
blue and disappears when the speed or put the engine under
engine is warmed up load.
Install a white smoke limiting
device (exhaust brake).
Install flame heater.
Install an engine heater.
Too much fuel in relation to air Injection timing too late Unit injectors misadjusted Adjust unit injector rocker
at low combustion arms.
temperatures Intake valve does not open Incorrect valve adjustment Adjust valve clearance.
properly
Faulty unit injector Replace
Leaky injector, dripping Replace
White Smoke, Water Vapor

Water in the combustion Leaky charge air cooler Test pressure (air - 0.5 bar
chamber [7.25 psi]; liquid - 4 bar [58
psi])
Leaky cylinder head gasket The fault is also present when
Cracked water-cooled the engine is hot
exhaust manifold
Cracked cylinder head (not If the fault is hard to trace:
cracks between valve seats) Change all cylinder heads for exchange cylinder heads or
pressure test all cylinder heads. Heat the cylinder heads
before pressurizing them.
Crack in cylinder liner

TROUBLESHOOTING Troubleshooting Chart
Black Smoke when Running / Under Load

Too much fuel in relation to air Injection timing too late Unit injectors misadjusted Adjust unit injector / rocker
at high combustion arms
temperatures Intake valve does not open Incorrect valve adjustment Adjust valve clearance.
properly
Faulty unit injector Replace unit injector
Leaky injector, dripping
Nozzle tip jams
Incorrect spray pattern from Clean or replace unit injector
nozzle
More than one gasket under
injector
Fault in turbocharger Check charge air pressure
Clogged air filter Replace
High exhaust backpressure Remove exhaust restriction
Worn intake valves Grind or lap valves
Clogged intake port Clean
Blue Smoke
Worn piston rings and / or Repair as necessary
cylinders
Oil leakage in turbocharger Check for oil in the intake
manifold after the
turbocharger
Damaged piston cooling Change damaged
nozzles nozzles
Gasoline in diesel oil
Fuel in the Oil

Dilution of oil in sump Unburned fuel passing the Worn piston rings Normally about 1% of fuel in
piston the lubricating oil per 200 hr of
operation
Defective injector Replace
Frequent cold starts
Worn engine Check “blow-by” in crankcase:
Correct value for new engine: 0 - +10 mmAq (0 - +0.014 psi)
(flow rate 60 - 100 l/min.)
Closed crankcase ventilation:-50 - +20 mmAq
(-0.071 - +0.028 psi)
Intake valve not opening Misadjusted valve or worn Adjust valve or replace
camshaft lobe camshaft

Troubleshooting Chart TROUBLESHOOTING
12/05
Oil in Coolant
Internal oil cooler leak with Pressure test the oil cooler
engine running Note: oil cooler test pressure: 10 bar (145 psi) oil on the oil
side, 0.5 bar (7.25 psi) air on the water side, immersed in water
25 - 27°C (77 - 81°F)
Defective cylinder head Replace
gasket
Crack in cylinder head (not If the fault is hard to trace:
between valve seats) Replace all cylinder heads or pressure test all cylinder heads.
Heat the cylinder heads before pressurizing them.
Coolant or Water in Oil

Dilution of oil in sump Internal oil cooler leaks when Pressure test oil cooler
engine is not running
Leaky O-rings at cylinder liner Leakage in telltale hole Change liner O-rings
Water is condensed in Engine does not reach normal
crankcase ventilation and operating temperature
runs down into the sump
Crack in cylinder head Run the engine until warm. Change the cylinder head for
Crack in water jacket on Remove the oil sump and all an exchange cylinder head.
cylinder block/cylinder head. side covers. If no leakage is found, change
(Coolant runs down through Pressure test the cooling all cylinder heads for
the pushrod hole) system. exchange cylinder heads
If coolant seeps out behind
Crack in water jacket on side covers or at the camshaft
cylinder head. (Coolant runs bearing, there is probably a
down via the oil duct for crack in one of the cylinder
rocker arm lubrication.) heads.
As a rule, it is possible to see
which cylinder head or heads
are leaking.
Cracked cylinder liner
Cracked water-cooled
exhaust manifold
Leakage in charge air cooler Test pressure (air - 0.5 bar
core [7.25 psi]; liquid - 4 bar
[58 psi])
Water enters via the Install a self-closing cover on
exhaust/intake system the exhaust pipe
Position the air cleaner so that
water cannot run into it

Low Oil Pressure

Gauge shows low pressure Defective sensor/instrument Test the oil pressure on warmed-up engine using a mechanical
pressure gauge directly on the engine
Incorrectly adjusted oil relief 1 shim = 0.2 bar (2.9 psi)
valve
Broken spring in oil relief Low max. oil pressure of 2 bar Check / repair relief valve
valve (29 psi) at 2000 rpm
Oil relief valve piston stuck in
open position
Incorrect crankshaft Maximum oil pressure 2 bar Change to bearings of the
bearing/main bearing size (29 psi) even with cold engine correct size. Check the
has been installed on bearing seats before
reground crankshaft assembly
Worn main or rod bearings Low oil pressure at idle - possibly Rebuild engine
accompanied by a knocking sound
Seizing in camshaft bearings If the bushing slides all the way out
of the bearing seat, the oil
pressure gauge reading will be
very low.
The engine throws out oil through
the crankcase ventilation
Loose piston cooling nozzle
Loose suction pipe to oil
pump, the pump sucks air
Engine too hot -
Extremely low lubricating oil Choose a viscosity that is
viscosity suitable for the ambient
temperature
Worn bushings or loose shaft Change rotor if bushing is
in oil cleaner worn oval
Change worn/damaged shaft
Broken O-ring on cyclone part
of oil cleaner
Defective oil pump drive
Internal leakage in oil cleaner Check that the oil centrifugal
cleaner is correctly assembled
Loosened guide plates in the
oil cooler preventing passage
of the oil
Worn/damaged oil pump
Clogged oil cooler
Loose screws in intermediate
timing gear

12/05

Gauge indicates low pressure The main oil passage (to Oil pressure at idle / low engine
at maximum speed but not at piston cooling nozzles) plug in speed is not affected since the
idling speed the rear of the engine is loose delivery valve closes at 3 bar (43.5
psi)
High Oil Pressure (Warm Engine)

Gauge indicates high Defective sensor / instrument Test the oil pressure on the warm engine using a mechanical
pressure pressure gauge directly on the engine
Oil viscosity too high Choose a viscosity that is
suitable for the ambient
temperature
Incorrectly adjusted oil relief 1 shim = 0.2 bar (2.9 psi)
valve
Piston in oil relief valve
jammed in closed position
Valve in oil duct to piston
cooling nozzles is binding
Abnormal Piston / Cylinder Wear

Short service life Unclean induction air due to Wear ridge (ring travel Install a more efficient air filter
inadequate filtering (wrongly shoulder) at piston top dead
dimensioned air filter) center
Unclean intake air due to
leakage in intake piping
Wrong grade of oil, polishing
damage
Changing of filters and oil has
been neglected
Low coolant temperature
(cold engine)
Excessive sulphur content in Change the fuel
fuel Change to oil with a higher
base number
Shorter oil change intervals
Defective injector (causes oil
film to be washed off)

Vibration - No Driven Components Engaged

Incorrect injection timing Adjust unit Injector
Individual injectors not Diagnose per separate EMS Replace defective component
operating manual
Flywheel has come loose
Crankshaft hub loose
Vibration or unusual noise at
1500 - 1700 rpm Defective vibration damper
Drive belts run off pulleys
Unsuitable rubber suspension Change to rubber elements of
and location different hardness
Weak engine bed Movement at engine Reinforce the engine bed
attachment points
Vibration - Transmission Engaged

Engine and propeller shaft Check engine alignment Align
misaligned
Bent propeller shaft Replace
Maximum boat speed is Bent propeller Replace
reduced Slipping transmission Repair
External Corrosion on Cylinder Liner

Unsuitable corrosion Flush the cooling system and
protection agent, glycol or fill with coolant as described
water in coolant in Engine Coolant on
page 3-13

12/05
Engine is Hard to Start

Air in fuel system Leak in suction pipe
The highest fuel level in the Install a “daily supply tank” at
tank is lower than the feed a higher location than the feed
pump. If the engine is not pump
operated for several days, the
fuel in the suction pipe may
run back to the tank because
of a leaky overflow valve
Leaky overflow valve
Low battery voltage
Ambient temperature too low Starting aids are not normally
needed at temperatures
above -15°C (5°F)
Oil viscosity too high
Paraffin precipitation in the
fuel
Blocked intake or exhaust
system
No fuel
Wrong injection timing
Faulty injector
Hydraulic Lock
Starter motor not powerful Leaky charge air cooler Test pressure (air 0.5 bar (7.25
enough to pull the piston over psi), liquid 4 bar (58 psi)
the compression stroke (if the Leaky cylinder head gasket
engine fires, a connecting rod
could be bent) Crack in cylinder head If the fault is hard to trace:
Change all cylinder heads for exchange cylinder heads or
pressure test all cylinder heads. Heat the cylinder heads
before pressurizing them.
Crack in cylinder liner Replace
Water has entered the engine Install a self-closing cover
via the exhaust or intake on the exhaust pipe
system Position the air cleaner so
that water cannot run into it
Crack in water-cooled
exhaust manifold
Injector open

Knocking
Exhaust valves close too late Timing gears incorrectly
and strike the piston crowns meshed
The crankshaft gear has
Check the valve timing
come loose
Valve mechanism not
operating
Rapidly increasing valve Oil flow problem to the rocker
clearances arms
The piston strikes the cylinder Loosened big end cap (wrong Tighten to the proper torque
head tightening torque after repair)
Foreign objects in the piston
crown
Piston seizure (may be
caused by clogged piston
cooling nozzles)
Wrong injection timing
Worn collets on exhaust
valves
Broken upper piston rings Incorrectly adjusted injectors
Connecting rod bearing
seizure
Faulty injector (seized, worn,
incorrect or cracked tip,
fatigued spring)
Incorrectly adjusted injector
More than one washer under
injector
Melting damage on piston Injection timing extremely Check the injection timing
crown advanced,
30° BTDC or more
Incorrectly adjusted injector

12/05
Excess Oil Consumption

Blue smoke under load Piston ring seizure
Piston seizure Combustion temperature too
high
Liner wear Unclean intake air
Carbon polishing Poor grade of oil
(in patches)
Piston ring wear
Piston rings stuck
Tapered piston rings installed
wrong way
Broken piston rings Individual piston rings broken = incorrectly fitted
Several upper rings broken = start spray used wrongly, wrong
injection timing (too early)
Several intermediate rings broken = worn rings or grooves
Worn valve guides Check the clearance between
valve and guide.
High exhaust temperature?
Poor grade of oil?
Oil level too high
Defective shaft seals in Check whether oil is present

turbocharger in the compressor or intake
manifold
Clogged air filter
Excessive vacuum in the air Measure the vacuum (max.

intake before the 500 mmAq [1.45 inHg])
turbocharger Check the air filter
Oil viscosity too low
Deformed/incorrectly directed
piston cooling
nozzles
External leakage
Excess Fuel Consumption

Faulty injector
Low charge air pressure
Manner of driving,
operating/load conditions

Low Cylinder Compression

Rough engine operation or Worn piston rings and
low power output cylinder
Broken piston rings
Incorrectly adjusted/ defective Perform compression test
valves
Hydrostatic lock/bent
connecting rod
Low Engine Output

Low fuel supply pressure Check the feed pump and overflow valve for leakage
(below 0.3 bar) Check for leakage in the suction pipe between tank and feed
pump
Clogged fuel filter/paraffin precipitation in fuel
Faulty injector
Fuel too hot
Incorrect fuel specification Check density and viscosity
Low charge air pressure Check charge air pressure
Abnormal pressure drop in Check the vacuum before the turbocharger,

intake piping maximum 500 mmAq
Check the air filter
Worn engine Check “blow-by” in crankcase
Closed crankcase ventilation: 50 - +20 mmAq
(-0.071 - +0.028 psi)
Leaky valves Take compression readings
and compare those of the
different cylinders
Incorrect injection timing Adjust unit injectors
Intake air temperature too Check the temperature of the
high air before the engine.
Above +25°C (77°F) will
reduce engine power
Exhaust backpressure too See Principal Engine
high Specifications on page 3-15.
Intake counter-pressure too See Low Charge Air Pressure
high on page 13-15

12/05
Engine Overheat
Instrument shows high Defective sensor/instrument Check that sensor and instrument match each other (120° and
temperature 150°C [248° and 302°F])
Check using a test thermometer
Low coolant level
Clogged seawater filter
Clogged freshwater/seawater Clean the cooling system
cooling system internally and externally
Pressure cap not operating Pressure test
Impeller on closed cooling or
seawater pump worn or
damaged
Incorrect comb / worn cover
on seawater pump
Restriction in coolant flow,
e.g. pieces of rubber from
seawater impeller
Cooling capacity too low Take a reading of the cooling
capacity
Combustion gas leakage Test compression
(causes loss of coolant)
Defective thermostats Check opening temperature
of thermostats
Reduced coolant flow Drive belts slip or pump pulley
loose on pump shaft
Air pockets in engine cooling Vent at the cooling system’s
circuit highest point
Check that the ventilation
piping to the coolant recovery
tank is not clogged
Excessive pressure drop in Check with forcibly opened
the external cooling system thermostats
Clogged heat exchanger
Cavitation damaged impeller
in coolant pump
Leakage in charge air cooler
Engine Runs Too Cold

Instrument indicates low Defective sensor/instrument Check that sensor and instrument match each other (120° and
temperature 150°C [248° and 302°F])
Check using a test thermometer
Thermostat jammed in open Check operation of
position thermostat

Coolant Loss
Defective cylinder head
gasket (external leakage)
External leakage
Coolant forced out of coolant Turbocharging pressure Test pressure (air - 0.5 bar
recovery tank enters cooling system via [7.25 psi]; liquid - 4 bar
leaking charge air element [58 psi])
White smoke when engine hot Crack in cylinder head (not If the fault is hard to trace: Change all cylinder heads for
indicates water vapor cracks between valve seats) exchange cylinder heads or pressure test all cylinder heads.
Heat the cylinder heads before pressurizing them.
Cracked cylinder liner Grey oil = coolant in oil Locate the leak by removing
the oil sump and pressurizing
the cooling system while
turning the engine over by
hand
Leaking cylinder head gasket Check for warped cylinder Replace cylinder head gasket
head
Contaminated Coolant
Faulty inhibitor Flush the cooling system and
Overdosed corrosion inhibitor refill with coolant as described
in Engine Coolant on
page 3-13
Engine Heater
Boiler scale on engine heater Incorrect mixture or type of Flush the cooling system and
glycol and/or corrosion fill it with coolant as described
inhibitor inEngine Coolant on
Antifreeze with page 3-13
phosphate-based inhibitor
must not be used
Short service life The heater is not designed for
continuous use. Suitable
temperature for thermostat
control = 40° - 60°C
High Oil Temperature

Instrument indicates too high Defective sensor / instrument Check using test
temperature thermometer
Poor water flow in oil cooler

12/05
High Exhaust Temperature

Wrong injection timing Check the injection timing Adjust unit injectors
Nozzle drips Check type, opening pressure Clean / replace unit injector
and general condition
High inlet air temperature Faulty intake air cooler
Low charge air pressure
Clogged air filter
Low Charge Air Pressure

Dirty / damaged Check/clean
turbine/compressor wheel in
turbocharger
Leakage between Check/change gaskets
turbocharger and cylinder
head
Bearing seizure in Check bearing play Recondition/change
turbocharger turbocharger
Clogged air filter Check the vacuum before the
turbocharger.
See Principal Engine
Specifications on page 3-15.
High fuel temperature
Low Fuel Pressure

Clogged fuel filter
Defective overflow valve
Defective feed pump
Air leakage in suction pipe
High pressure drop in suction
pipe

Low System Voltage

Normal charging voltage: Broken alternator drive belt
27 - 28 V Slipping alternator drive belt
Batteries in poor condition
Alternator fault
Voltage regulator fault
Battery charger fault
High System Voltage

Normal charging voltage: Voltage regulator fault
27 - 28 V Battery charger fault
External Oil Leakage

Crankcase pressure too high Check “blow-by” in crankcase
Closed crankcase ventilation: -50 - +20 mmAq (-0.071 -
+0.028 psi)
Leaky crankshaft seal
Leakage at liner seal via
overflow hole in cylinder block
gasket
Leakage in manifold joint Low load
External Coolant Leakage

Leakage in cylinder liner seal
Cold leakage Replace hoses using better
quality hoses (preferably
silicone)
gasket
Coolant pump leakage Check at the water pump
housing’s weep hole
Leakage at charge air cooler
connection

12/05
Oil Forced Out Crankcase Ventilation

Hole in piston crown Increases when white smoke
limiting device is engaged or
exhaust brake applied
Bearing seizure in
turbocharger
Oil seepage via pistons - liner
Turbocharger Failure
Loss of power Excessive bearing play in
turbocharger
Lubrication piping between Check the connections
turbocharger and filter
incorrectly connected

TROUBLESHOOTING Fault Codes
FAULT CODES
Fault codes will be displayed on the digital display.
Interpretation of those codes can be found in
publication supplied with the unit.
Working Procedure
Try to form a comprehensive view of the problem.
Start by asking the user the following:
• Fault symptoms
• Conditions in which the fault occurs
• How often the fault occurs
• If the fault codes have been erased
Then, present all the stored fault codes.
Compare them and try to conclude the probable
cause of the fault before taking any other
measures. The fault codes are stored in the order
they were registered.
AFTER TROUBLESHOOTING OR
REPAIR
The engine control unit may have generated fault
codes due to the current fault or during
troubleshooting. Do not forget to check and clear
any fault codes.

Yanmar 6 SY-STP2

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6SY / 8SY Service Manual

Table of Contents .................................................................................. 2-i

6SY / 8SY Service Manual iii

This Page Intentionally Left Blank

iv 6SY / 8SY Service Manual

6SY / 8SY Service Manual 1-1

Revision Control Table

1-2 6SY / 8SY Service Manual

This safety alert symbol appears

6SY / 8SY Service Manual 2-1

Avoid personal injury. ALWAYS read and follow

Wipe up all spills immediately.

2-2 6SY / 8SY Service Manual

Avoid personal injury. If the vessel has more than

To prevent accidental equipment movement,

6SY / 8SY Service Manual 2-3

Lifting Hazard The safety messages that follow have CAUTION

2-4 6SY / 8SY Service Manual

Make sure the engine is installed on a level surface.

Only use replacement parts specified. Other

NEVER attempt to modify the engine design or

Modifications may impair the engine’s safety and

If any indicator illuminates during engine operation,

6SY / 8SY Service Manual 2-5

This Page Intentionally Left Blank

2-6 6SY / 8SY Service Manual

6SY / 8SY Service Manual 3-1

3-2 6SY / 8SY Service Manual

NEVER turn off the battery switch (if equipped) or

6SY / 8SY Service Manual 3-3

247 min/255 max

252 min/260 max Unloaded

6SY / 8SY Service Manual

Sea water inlet, Ø54

6SY / 8SY Service Manual

ENGINE PIPING DIAGRAMS Figure 3-48SY Fuel Flow

(10) (6) (11) (7) 0003538

1 – Fuel Feed Pump Assembly

3-6 6SY / 8SY Service Manual

Figure 3-56SY Cooling Flow

1 – Bypass Channel 13 – Cooler for Gearbox Oil

6SY / 8SY Service Manual 3-7

Figure 3-68SY Cooling Flow

1 – Heat Exchanger Element, Main Section 11 – Ventilation Line

3-8 6SY / 8SY Service Manual

LOCATION OF NAMEPLATES Figure 3-88SY Engines

The following figures show the location of

Engine Nameplate (Typical)

6SY / 8SY Service Manual 3-9

DIESEL FUEL • Fuel additives are not recommended. Some fuel

specifications. The table lists several worldwide 1 4

Additional Technical Fuel Requirements 1 – Fuel Filter

• Never use Biocide or mix winter and summer

3-10 6SY / 8SY Service Manual

Filling the Fuel Tank Bleeding the Fuel System

6SY / 8SY Service Manual 3-11

ENGINE OIL Additional Technical Engine Oil

• API Service Categories CD or higher SAE 10W

• API Classification (American Petroleum Institute)

3-12 6SY / 8SY Service Manual

Maximum Angles of Inclination During ENGINE COOLANT

coverage, cause an internal buildup of rust and

Coolant (Closed Cooling System)

c: Check or Clean : Replace

c: Check or Clean : Replace